Patent Application
20070227040
This invention relates to foot-supporting structures (such as sole structures, including midsole members or outsole members or combinations thereof) for footwear or other foot-receiving devices, as well as to foot-receiving device products containing such structures.
Conventional articles of athletic footwear have included two primary elements, namely an upper member and a sole member or structure. The upper member provides a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper member may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure generally is secured to a lower portion of the upper member and generally is positioned between the foot and the ground or other contact surface. In addition to attenuating ground reaction forces, the sole structure may provide traction and control foot motions, such as pronation. Accordingly, the upper member and the sole structure operate cooperatively to provide a comfortable structure that is suited for a variety of ambulatory activities, such as walking and running.
The sole member or structure of athletic footwear generally exhibits a layered configuration that includes a comfort-enhancing insole, a resilient midsole formed from a polymer foam material, and a ground-contacting outsole that provides both abrasion-resistance and traction. The midsole is the primary sole structure element that attenuates ground reaction forces and controls foot motions. Suitable polymer foam materials for the midsole include ethylvinylacetate or polyurethane that compress resiliently under an applied load to attenuate ground reaction forces. Conventional polymer foam materials are resiliently compressible, in part, due to the inclusion of a plurality of open or closed cells that define an inner volume substantially displaced by gas.
Aspects of this invention relate to support structures for foot-receiving devices, such as midsole and/or outsole structures for articles of footwear. Such support structures may include one or more of the following:
Additional aspects of this invention relate to foot-receiving devices structures, such as articles of footwear (e.g., athletic footwear) that including support structures having one or more of the features described above. In addition to the support structures described above, foot-receiving device structures in accordance with at least some examples of this invention may include a foot-covering member, such as an upper member (e.g., made from an unstretchable upper material), attached to at least some portion of the support structure. Such foot-receiving device structures further may include an interior member, such as a bootie element (e.g., made from a soft, comfortable, and/or stretchable material), engaged with at least one of the upper member and/or the support structure, wherein the bootie element at least partially defines a foot-receiving chamber. If desired, the bootie element may include a heel-surrounding portion, a lateral side portion, a medial side portion, and a seamless plantar portion in a continuous, one-piece arrangement. Additionally or alternatively, if desired, the bootie element may include a double layer of bootie material, e.g., at least in an Achilles area portion thereof.
The present invention is illustrated by way of example and is not limited in the accompanying figures, in which like reference numerals indicate similar elements throughout, and in which:
In the following description of various examples of the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example articles of footwear, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, articles of footwear, other foot-receiving devices, example systems, and environments may be utilized and take advantage of features of the invention, and structural and functional modifications may be made from the specific examples disclosed without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “side,” “front,” “back,” “above,” “below,” “under,” “over,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures and/or a typical orientation during use. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention.
To assist the reader, this specification is broken into various subsections, as follows: Terms; General Description of Aspects of the Invention; Specific Examples of Bootie and Foot-Receiving Device Structures According to the Invention; and Conclusion.
The following terms are used in this specification, and unless otherwise noted or clear from the context, these terms have the meanings provided below.
“Foot-receiving device” means any device into which a user places at least some portion of his or her foot. In addition to all types of “footwear” (described below), “foot-receiving devices” include, but are not limited to: bindings and other devices for securing feet in snow skis, cross country skis, water skis, snowboards, and the like; bindings, clips, or other devices for securing feet in pedals for use with bicycles, exercise equipment, and the like; bindings, clips, or other devices for receiving feet during play of video games or other games; and the like.
“Footwear” means any type of product worn on the feet, and this term includes, but is not limited to: all types of shoes, boots, sneakers, sandals, thongs, flip-flops, mules, scuffs, slippers, sport-specific shoes (such as basketball shoes, golf shoes, tennis shoes, baseball cleats, soccer or football cleats, ski boots, etc.), and the like. “Footwear” may protect the feet from the environment and/or enhance a wearer's performance (e.g., physically, physiologically, medically, etc.).
“Foot-covering members” include one or more portions of a foot-receiving device that extend at least partially over and/or at least partially cover at least some portion of the wearer's foot, e.g., so as to assist in holding the foot-receiving device on and/or in place with respect to the wearer's foot. “Foot-covering members” include, but are not limited to, upper members, e.g., of the type provided in some conventional footwear products.
“Foot-supporting members” include one or more portions of a foot-receiving device that extend at least partially beneath at least some portion of the wearer's foot, e.g., so as to assist in supporting the foot and/or attenuating the reaction forces to which the wearer's foot would be exposed, for example, when stepping down, landing a jump, and/or otherwise using the foot-receiving device. “Foot-supporting members” include, but are not limited to, sole members, e.g., of the type provided in some conventional footwear products. Such sole members may include conventional outsole, midsole, and/or insole members.
“Ground-contacting elements” or “members” include at least some portions of a foot-receiving device structure that contact the ground or any other surface in use, and/or at least some portions of a foot-receiving device structure that engage another element or structure in use (e.g., engage another part of a video game structure, etc.). Such “ground-contacting elements” may include, for example, but are not limited to, outsole elements, e.g., like those provided in some conventional footwear products. “Ground-contacting elements” in at least some example structures may be made of suitable and conventional materials to provide long wear, traction, and protect the foot and/or to prevent the remainder of the foot-receiving device structure from wear effects, e.g., when contacting the ground and/or engaging another surface or structure in use.
In the description that follows, various connections and/or engagements are set forth between elements in the overall structures. The reader should understand that these connections and/or engagements in general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect.
A. Interior Member/Bootie Structures
Aspects of this invention relate to structures used in articles of footwear or other foot-receiving devices, e.g., including structures for contacting and/or holding a wearer's foot.
Some more specific example structures and aspects of this invention relate to interior members, such as bootie structures, for foot-receiving device interiors (such as the interior chamber of an article of footwear, such as athletic footwear (e.g., basketball sneakers, high top or ankle covering footwear, etc.)). Bootie structures in accordance with at least some examples of this invention may include a first material element at least partially defining a foot-receiving chamber. The material element in this example bootie structure may include a heel-surrounding portion, a lateral side portion, a medial side portion, and a seamless plantar portion, wherein the first material element includes the plantar portion, the heel-surrounding portion, the lateral side portion, and the medial side portion in a one-piece and/or seamless arrangement. Bootie structures in accordance with at least some examples of this invention further may include a tongue portion included as part of or engaged with the first material element, wherein this tongue portion at least partially defines an instep portion of the foot-receiving chamber.
As noted above, bootie structures in accordance with at least some examples of this invention may include the plantar portion, the heel-surrounding portion, the lateral side portion, and the medial side portion as a continuous, one-piece arrangement. In such bootie structures, a first seam may join a lateral edge of the heel-surrounding portion with a lateral edge of the lateral side portion, and a second seam may join a medial edge of the heel-surrounding portion with a medial edge of the medial side portion. If desired, in at least some structures, the lateral side portion and the medial side portion of the bootie may be seamless and contiguous with the plantar portion, thereby providing a comfortable, smooth, seam-free surface for the plantar and side regions of the foot. Additionally, when present, the tongue portion of the bootie structure may be joined to the first material element via at least a third seam that joins a lateral edge of the tongue portion with a lateral edge of the lateral side portion and/or a fourth seam that joins a medial edge of the tongue portion with a medial edge of the medial side portion. Alternatively, if desired, the tongue portion may be continuously formed with at least one of the lateral or medial side portions and/or the front portion of the bootie structure such that at least one seam or a portion thereof may be eliminated.
Providing an interior bootie member having a seamless plantar portion, as described above, can provide a very comfortable fit. Other features of at least some example structures according to the invention also can help provide various fit features. For example, if desired, when using a bootie member in accordance with at least some examples of this invention, a conventional insole member, sock liner element, or the like can be eliminated. In effect, in such structures, there can be direct contact between the wearer's foot (optionally with a sock on) and the bootie member. Also, if desired, there can be direct contact between the bootie member and a midsole or other impact-attenuating element of the footwear structure. These features can help provide a comfortable, “lower” fit and footwear structure (e.g., an overall thinner sole structure and/or heel portion in the final footwear product), and they also can enable the footwear structure to better conform to the wearer's foot (e.g., by allowing the upper member to better conform to the midsole structure and/or the wearer's foot). Also, elimination of insole members and/or sock liners from the footwear structure can eliminate bulk and/or at least one adhesive layer from the overall footwear structure, as well as the corresponding stiffness associated with inclusion of such adhesives and/or bulk.
Aspects of this invention also relate to foot-receiving device interior members (such as interior booties for articles of footwear, including athletic footwear, such as sneakers, tennis shoes, high top shoes, basketball shoes, etc.) that include a first material element (e.g., a soft fabric or foam material) at least partially defining a foot-receiving chamber, wherein a double layer of the material element is provided at least along an Achilles area portion of the interior member structure. If desired, the foot-receiving device interior member additionally may include one or more of a heel-surrounding portion, a lateral side portion, a medial side portion, a plantar surface, an ankle-containing portion, etc., e.g., to form a complete bootie structure, in some examples. In the final foot-receiving device structure, one layer of the double layer of the material element in the Achilles area may remain exposed and open (and optionally attached to an upper member or other foot-covering member structure), thereby forming a portion of the exterior of the foot-receiving device structure. If desired, the entire interior member may be made from the first material element (e.g., to form an entire bootie structure), optionally with a seamless plantar surface. Alternatively, if desired, the interior member may be made from multiple pieces without departing from the invention, including potentially multiple pieces for any of the heel-surrounding portion, the lateral side portion, the medial side portion, and/or the plantar surface, as well as multiple pieces making up these individual portions.
As another example, a second material element, e.g., including a tongue portion, may be engaged with the first material element to, at least in part, define an instep portion of the foot-receiving chamber. If desired, the entire interior member may be made from only the first and second material elements.
If desired, other portions of the foot-receiving chamber may be made from a double layer of the interior member material (in addition to or in place of the Achilles area portion). For example, either or both of an extended lateral ankle edge portion or an extended medial ankle edge portion (e.g., along the rim of the foot-receiving chamber) may be made from a double layer of the interior member material.
B. Interior Member/Bootie Blanks
Still additional aspects of this invention relate to interior member/bootie blanks, e.g., blanks suitable for making interior member/bootie structures of the various types described above. Such blanks may include a first material element defining: (a) a plantar region, (b) a heel-containing region extending from a first side of the plantar region, the heel-containing region defining a first free end of the bootie blank, (c) a lateral side region extending from a second side of the plantar region, the lateral side region including a lateral side edge extending in a direction toward the heel-containing region, and (d) a medial side region extending from a third side of the plantar region, the medial side region including a medial side edge extending in a direction toward the heel-containing region. The heel-containing region may include a lateral heel edge extending in a direction from the first end toward the lateral side edge and a medial heel edge extending in a direction from the first end toward the medial side edge. The lateral heel and side edges may extend to a location proximate to one another (e.g., to a common point) and define edges to be engaged together when forming a bootie structure (e.g., via a sewn seam, etc.). Similarly, the medial heel and side edges may extend to a location proximate to one another (e.g., to a common point) and define edges to be engaged together when forming a bootie structure (e.g., via a sewn seam, etc.). In accordance with at least some examples of this invention, the first material element includes at least the plantar region, the lateral side region, and the medial side region in a continuous, seamless arrangement.
Bootie blanks in accordance with at least some examples of this invention may include another element, such as a tongue portion. The tongue portion may be included on a second, separate material element, or it may be included as part of the first material element (e.g., optionally formed continuously with either of the lateral or medial side regions, optionally formed continuously with the plantar region, optionally formed on the same material element but discontinuous and/or separated from the plantar region, the heel-containing region, the lateral side region, and the medial side region, etc.). The blanks may be sized and structured to fit any desired footwear or foot-receiving device constructions, such as low top athletic footwear, high top athletic footwear, etc.
Still additional aspects of this invention relate to foot-receiving device interior member blanks that include a first material element defining an extended Achilles area engaging portion for forming a double layer of the material element in an Achilles area when forming a foot-receiving device interior member structure. The first material element also may include one or more of: a plantar region; a heel-containing region contiguous with and extending from a first side of the plantar region, the heel-containing region defining a first end of the blank; a lateral side region contiguous with and extending from a second side of the plantar region; a medial side region contiguous with and extending from a third side of the plantar region; and/or a tongue portion (optionally discontinuous from the plantar region, the heel-containing region, the lateral side region, the medial side region, and/or the extended Achilles area engaging portion on the first material element). Alternatively, if desired, the tongue portion and/or other portions of the blank may be contained on a separate material element from the first material element. The blank may form an overall bootie structure that may be included in an article of footwear or other foot-receiving device structure.
Optionally or alternatively, if desired, the first material element for the blank may be structured so as to provide a double layer of the material element at either or both of an extended lateral ankle area engaging portion or an extended medial ankle area engaging portion (e.g., along the rim of the foot-receiving chamber), with or without the double layer of the material element provided at the Achilles area engaging portion.
The interior member may be formed from any desired material without departing from the invention. In accordance with at least some examples of this invention, at least the first material element of the interior member structure will be constructed from a stretchable material (e.g., stretchable in at least one and preferably multiple directions). The material, in at least some examples, may have at least one non-porous component or layer, e.g., to prevent or inhibit moisture penetration and/or adhesive bleed through, e.g., when the interior member structure is included in a foot-receiving device. If desired, the material element may have a multi-layer structure, including, for example, one or more non-porous layers (such as a batting material layer, etc.), an impact-attenuating layer (such as a foam layer made of polyurethane, ethylvinylacetate, or other desired material, etc.), one or more fabric materials, and/or other desired layers or materials, and this multi-layered material then may be folded over or otherwise doubled up to provide the double layer of the material element. As still additional examples, the interior member may be a breathable material that allows exhaustion of heat, moisture, and/or air to the exterior, optionally while preventing at least some degree of moisture and/or adhesive transfer from the interior member exterior to its interior.
Bootie blanks of the types described above also may be incorporated into an article of footwear structure without the need to include an additional insole member, sock liner, or the like. The elimination of insole members, sock liners, and the like from the overall footwear structure can be useful to provide a comfortable fit, lower structure, and/or other properties as described above.
C. Impact-Attenuating Elements and Other Foot-Supporting Members
Additional aspects of this invention relate to impact-attenuating elements for foot-receiving devices. Such elements may include: (a) a base member including (e.g., at least partially formed from) an impact-attenuating material, the base member including a front portion, a rear portion, a medial side portion, and a lateral side portion; and (b) a moderator element engaged with the base member, wherein the moderator element includes a first leg member, a second leg member, and a base portion connecting the first and second leg members, wherein each leg member includes a free end located at or toward the front portion of the base member, and each leg member extends from its free end toward the base portion located at or toward the rear portion of the base member with respect to the free ends' locations. In at least some examples, the impact-attenuating elements will provide or form at least a portion of a sole structure (such as a midsole member or a combination midsole/outsole member) for articles of footwear. Such structures including moderator elements of the types described above may help control the flex point of footwear and/or control midfoot torsion.
If desired, additional portions of moderator material may extend between the leg members, e.g., at one or more locations between the free ends and the base portion (e.g., along the arch area to provide additional support). Also, if desired, more than two leg members may be provided and/or one or more of the leg members may have additional branches extending therefrom without departing from this invention.
Impact-attenuating elements in accordance with at least some examples of this invention further may be engaged with other structural elements of a foot-receiving device. For example, the impact-attenuating element may be engaged with a ground-contacting member (such as a footwear outsole structure), a foot-contacting member (such as an insole, an interior bootie element, etc.), a foot-covering member (such as an upper member), a joint covering band or wrap (e.g., a foxing band), a heel counter member, and/or the like.
Moderator elements included in impact-attenuating elements according to the invention may take on any desired form without departing from the invention. In at least some examples, the moderator element will have a thin plate or sheet like structure, e.g., made from fiberglass, plastic (e.g., injected plastic, such as thermoplastic polyurethane), metal, combinations thereof (e.g., 30% glass fiber in nylon 66, etc.), or other suitable material, and it may be attached to an exterior surface of the base member or at least partially included within the base member. In at least some examples, the moderator element will be flexible so as to allow at least some degree of medial-lateral splay and conformance in the forefoot portion (e.g., due to the free ends of the element) and will create an appropriate level of flexibility and/or a flex point at the metatarsophalangeal joint, while also providing at least moderate torsional rigidity and moderated deflection in the heel region (e.g., due to the base portion and its relative stiffness and inflexibility as compared to the stiffness and flexibility characteristics at the free ends).
D. Impact-Attenuating Elements and Foot-Supporting Structures
As noted above, aspects of this invention relate to impact-attenuating elements for foot-receiving device structures, such as midsole structures or other sole structures for articles of footwear. Impact-attenuating elements in accordance with at least some examples of this invention may include: (a) a base member including (e.g., at least partially formed from) an impact-attenuating material, the base member including a front portion, a rear portion, a medial side portion, and a lateral side portion; and (b) an edge element extending from a first surface of the base member, the edge element located along at least a portion of a perimeter of the lateral side portion of the base member (e.g., at and around the fifth metatarsophalangeal joint). This edge element may be structured so as to have sufficient height to engage a lateral side of a foot in use (e.g., to help stabilize the foot and/or maintain it in position with respect to the first surface). If desired, in accordance with at least some examples of this invention, the edge element may be integrally formed as a single piece with the base member (e.g., the edge element may be molded along with the base member as a single piece of material). Also, if desired, a perimeter rim element may be provided around all or substantially all of the base member, and the edge element may be provided in the lateral side portion to extend above at least some portions of the remainder of the perimeter rim element.
Optionally, in at least some example structures, the edge element of the impact-attenuating element may include one or more discontinuity regions along the lateral side portion of the base member (e.g., slits, cuts, gaps, overlapping structures, etc.). Such discontinuity regions may help the impact-attenuating element better bend or flex, conform to foot movements or location changes, etc. Siping or other breaks or discontinuities in the bottom surface or other portions of the base member and/or all the way through the base member (e.g., in generally the longitudinal direction thereof) also may enhance splay and/or conformance of the foot-supporting member to the wearer's foot and/or to the contact surface.
Again, other elements may be included as part of and/or engaged with the impact-attenuating elements without departing from this invention. For example, other elements typically included in an article of footwear or other foot-receiving device structure may be included and/or engaged with the impact-attenuating element without departing from this invention. More specific examples of such elements include: ground-contacting members (which may be engaged with a second surface of the base member opposite the first surface, such as outsole members); heel counter elements; insoles, booties, sock liners, or other foot-contacting or containing members; upper members or other foot-covering members; joint covering elements, such as foxing wraps or bands; etc.
As noted above, ground-contacting members, such as outsole elements, may be included with the impact-attenuating elements described above (e.g., engaged via adhesives, stitching, or the like). Such ground-contacting members may include a perimeter element, e.g., extending from its first major surface, wherein the perimeter element is located at least at a position corresponding to a location of the edge element of the base member and at least partially overlaps and/or contains the edge element of the base member. This joint between the perimeter element and the edge element (and/or optionally the upper member), in at least some examples, may be covered by an additional foxing strip or band member, e.g., extending along at least a portion of the perimeter of the base member that includes the edge element of the base member. The foxing strip also may cover at least a portion of the ground-contacting member, the upper member, a toe cap member, etc.
E. Foot-Supporting Members Including Sole Members for Footwear and Other Foot-Receiving Devices
Aspects of this invention relate to foot-supporting members, including ground-contacting members, that may be used in foot-receiving devices (e.g., in sole members, including outsole members, that may be used in articles of footwear). A foot-supporting member (e.g., a sole structure) according to at least some examples of this invention may include: (a) a first major surface including: (i) a plurality of ridge elements extending in a first direction (e.g., a direction extending generally from a lateral side to a medial side of the foot-supporting member structure), and (ii) a plurality of recess regions extending in the first direction, wherein an alternating structure of ridge elements and recess regions is provided in a second direction (e.g., a direction extending generally from a forefoot portion to a rearfoot portion of the foot-supporting member structure); and (b) a second major surface opposite the first major surface, the second major surface including: (i) a plurality of ridge elements extending in the first direction, and (ii) a plurality of recess regions extending in the first direction. In this structure, the ridge elements of the second major surface correspond to a back side of corresponding recess regions of the first major surface, and the recess regions of the second major surface correspond to a back side of corresponding ridge elements of the first major surface. The first and second major surfaces may form the exterior and interior surfaces of a footwear outsole member. Foot-supporting structures of this type can provide very supple shoe/foot and/or shoe/ground interfaces, e.g., with good conformance of the foot-supporting member to the foot and/or ground.
The overall foot-supporting member structure may include other elements as well, such as an impact attenuating material (e.g., a midsole structure), attached to one of the major surfaces of the foot-supporting member. In at least some examples, the first and second major surfaces will be constructed as described above and from a suitable material (e.g., a flexible polymeric material) such that adjacent ridge elements of the first surface splay apart at least somewhat under an applied force in a direction having a component perpendicular to the second major surface (e.g., when a wearer's steps down, changes directions, lands a jump, and/or otherwise applies a force to ridge elements of the second major surface). Application of force with at least a component in the horizontal direction (e.g., or parallel to the contact surface) also may cause splay of some adjacent ridge elements and conformance of the sole structure to the foot and/or ground, in at least some examples of this invention. Also, if desired, portions of the foot-supporting member including the ridge elements and recess regions (e.g., portions of an outsole structure) may be somewhat thinner than other regions of the foot-supporting member structure (e.g., thinner than at least some outsole portions not containing ridge elements and/or recess regions), which can help produce the splay properties described above.
If desired, an impact-attenuating material may be included to at least partially fill at least some of the recess regions of one of the major surfaces (e.g., the unexposed surface to be included in the interior of the foot-receiving device). This impact-attenuating material (e.g., a relatively soft polyurethane) may be somewhat softer than the material making up the first and second major surfaces, and if desired, this material may completely fill the plurality of recess regions of the major surface, e.g., so as to provide a substantially smooth, comfortable, and even major surface.
If desired, in accordance with at least some examples of this invention, the foot-supporting member structure may include a perimeter element extending along at least a portion of a perimeter of the second major surface (e.g., to provide a raised edge or rim around at least a portion of the perimeter). This perimeter element may extend completely around the perimeter of the second major surface, if desired. A midsole member or other impact-attenuating element may be included within the perimeter element. If desired, in accordance with at least some examples of this invention, the perimeter element may include a raised portion along a lateral mid-foot and/or front-foot portion, e.g., near the user's lateral-most toe (e.g., at the fifth metatarsophalangeal joint), which may help to support the lateral side of a user's foot (e.g., particularly during side-to-side motions, direction changes, etc.). The raised portion along the lateral mid-foot and/or front-foot portion may extend somewhat higher than some or all of the remainder of the perimeter element.
In at least some example structures according to the invention, at least some of the ridge elements and at least some of the recess regions of the first major surface will continuously extend essentially completely across the structure, e.g., from the lateral side to the medial side. The term “essentially completely across,” as used herein and in this context, means that the ridge elements and recess regions extend across at least 75% of the structure in a given direction (e.g., from the lateral side to the medial side), and in some examples it will extend at least 90% of this distance. The ridge elements and recess regions of the first major surface may have a zig-zag structure in the first direction and/or at least some of the ridge elements and the recess regions of the first major surface may produce a herringbone pattern. Optionally, the herringbone pattern, when present, may cover a majority of the first major surface (e.g., at least 50% of the major surface area, and in some more specific examples, at least 75% or 90% of the major surface area).
F. Combinations of Features
Additional aspects of this invention relate to combinations of two or more of the various features, components, and/or aspects of the invention described above. Such combinations may include, for example, two or more of: (a) an interior member and/or upper member structure with a continuous and/or seamless plantar region, (b) an interior member structure with a double layer of material at the Achilles-engaging portion (and optionally other areas), (c) an impact-attenuating member with a moderator element included therein, (d) an impact-attenuating member with an additional lateral support structure, (e) a contact surface-contacting member with an additional lateral support structure, (f) a contact surface-contacting member with ridge and recess regions, and/or (g) an upper member, e.g., of a substantially unstretchable material. The various features, components, and/or aspects of the invention described above further may be provided in combination with other features, elements, and components, such as features, elements, and/or components provided in conventional footwear structures.
G. Foot-Receiving Device Structures
Still additional aspects of this invention relate to foot-receiving device structures (such as articles of footwear) that include one or more of the various components, features, and/or aspects of the invention described above. As one example, such foot-receiving devices may include: (a) an interior member/bootie element defining a foot-receiving chamber, the interior member/bootie element including a first material element having a heel-surrounding portion, a lateral side portion, a medial side portion, and a seamless plantar surface, wherein the first material element includes the plantar portion, the heel-surrounding portion, the lateral side portion, and the medial side portion in a continuous, one-piece arrangement; and (b) a first foot-receiving device component engaged with the interior member/bootie element. Optionally, if desired, the interior member/bootie element further may include a tongue portion, e.g., optionally formed from the first material element or from a second material element engaged with the first material element. The tongue portion may at least partially define an instep portion of the foot-receiving chamber.
Still additional aspects of this invention relate to foot-receiving device structures (such as articles of footwear) that include: (a) an interior member at least partially defining a foot-receiving chamber, the interior member including a first material element having a double layer of the material element along an Achilles area portion; and (b) a first foot-receiving device component engaged with the interior member. The first material element making up the interior member (which may be made from a stretchable, soft fabric or foam material) further may include one or more of a heel-surrounding portion, a lateral side portion, a medial side portion, a plantar surface, an ankle-containing portion, a tongue portion, etc. Alternatively, if desired, at least some portion of the tongue may be provided as a second material element engaged with the first material element, e.g., at an instep portion of the foot-receiving chamber, along the lateral, medial, or plantar portions, etc. Additionally or alternatively, as described above, a double layer of the interior member material may be provided along an extended lateral or medial ankle edge portion of the foot-receiving chamber (e.g., along a rim of the foot-receiving chamber).
The first foot-receiving device component engaged with the interior members/bootie elements described above may take on a wide variety of different forms without departing from this invention. As some more specific examples, this first foot-receiving device component may include: a tongue cover element; at least a portion of a sole member for an article of footwear (such as a portion of a midsole member); at least a portion of an upper member for an article of footwear (e.g., an unstretchable or substantially unstretchable material, such as a canvas or leather material (e.g., less than 30% stretch in any direction, and optionally less than 15% stretch in any direction), forming a major portion of the upper member, etc.); a heel counter; an impact-attenuating material (such as a polyurethane foam material); another type of foot-supporting member element; another type of foot-covering member element; etc. Also, multiple foot-receiving device components may be engaged with the interior member/bootie element, directly or indirectly, with any desired piece thereof (if multiple pieces are present), without departing from the invention.
Still additional aspects of this invention relate to foot-receiving devices, including articles of footwear, that include impact-attenuating elements or other foot-supporting members, e.g., of the various types described above (such as sole members, including midsole elements or midsole/outsole combination members). Foot-receiving devices (e.g., articles of footwear) according to at least some examples of this invention may include: (a) a foot-covering member (such as an upper member); and (b) a foot-supporting member engaged with the foot-covering member (such as a midsole member or other sole structure) that includes: (i) a base member including an impact-attenuating material, the base member including a front portion, a rear portion, a medial side portion, and a lateral side portion; and (ii) a moderator element engaged with the base member. The moderator element may take on the various structures described above, such as it may include at least a first leg member, a second leg member, and a base portion connecting the first and second leg members, wherein each leg member includes a free end located at or toward the front portion of the base member, and each leg member extends from its free end toward the base portion located at or toward the rear portion of the base member as compared with the free ends' locations. As noted above, the moderator element may include additional elements, such as additional leg members, branches from one or more of the leg members, additional elements or portions connecting the leg members, etc. The moderator element may be engaged with or included within the base member (partially or completely within) without departing from this invention. The overall foot-receiving device structure further may include a ground-contacting element, such as an outsole member, a foot-contacting member (such as a bootie element or an insole member), a heel counter, a foxing wrap or band, a toe cap, and/or other footwear features without departing from this invention.
Additional aspects of this invention relate to foot-receiving devices, such as articles of footwear, that include: (a) a foot-covering member (such as an upper member); and (b) a foot-supporting member (such as a sole structure or a portion of a sole structure) directly or indirectly engaged with the foot-covering member that includes: (i) a base member including an impact-attenuating material, the base member including a front portion, a rear portion, a medial side portion, and a lateral side portion; and (ii) an edge element extending from a first surface of the base member, the edge element located along at least a portion of a perimeter of the lateral side portion of the base member, wherein the edge element has sufficient height to engage (e.g., support, contain, abut against, prevent the movement of, etc.) a lateral side of a foot in use (e.g., at the fifth metatarsophalangeal joint). If desired, the foot-supporting member may include at least a midsole member for an article of footwear. The foot-supporting member further may include one or more of: a ground-contacting member, such as an outsole member; a foot-contacting member, such as an insole member, sock liner, or a bootie element; a heel counter; a foxing band or wrap; etc. The ground-contacting member may include an edge element having sufficient height to engage (e.g., support, contain, abut against, prevent movement of, etc.) the edge element of the base member and/or the lateral side of a user's foot.
Additional aspects of this invention relate to foot-receiving devices, such as articles of footwear, that include: (a) a foot-covering member (such as an upper member for an article of footwear); and (b) a foot-supporting member (such as a sole member for an article of footwear) engaged with the foot-covering member, wherein the foot-supporting member includes a ground-contacting member (such as an outsole member for an article of footwear). The ground-contacting member may include: (a) an exposed first major surface including: (i) a plurality of ridge elements extending in a first direction (e.g., in a direction extending generally from a lateral side to a medial side of the foot-supporting member), and (ii) a plurality of recess regions extending in the first direction, wherein an alternating structure of ridge elements and recess regions is provided in a second direction (e.g., in a direction extending generally from a forefoot portion to a rearfoot portion of the foot-supporting member); and (b) a second major surface opposite the first major surface, the second major surface including: (i) a plurality of ridge elements extending in the first direction, and (ii) a plurality of recess regions extending in the first direction. In this structure, the ridge elements of the second major surface correspond to a back side of corresponding recess regions of the first major surface and the recess regions of the second major surface correspond to a back side of corresponding ridge elements of the first major surface. This foot-supporting member may provide a supple shoe/foot and/or shoe/ground interface and have excellent conformance to a user's foot and/or to the ground.
Foot-receiving devices according to the invention may take on any desired form or structure. For example, the foot-covering member (e.g., the upper member) may be made of any desired materials, including one or more of: leathers (natural or synthetic); rubbers (natural or synthetic); polymers; fabrics (canvas materials); substantially unstretchable materials (e.g., less than 30% stretch in any direction, and optionally less than 15% stretch in any direction); and the like. The foot-receiving device may have a “high top” type construction (e.g., including an upper member having an ankle-covering portion), a “low top” type construction (e.g., including an upper member that leaves at least some portion of the ankle exposed), etc. Any type of footwear may take advantage of various aspects of this invention, including, for example, athletic footwear, such as sneakers, basketball shoes, and the like.
Foot-receiving device structures according to the invention also may include combinations of two or more of the various features, components, and/or aspects described above.
Given the general description of various examples and aspects of the invention provided above, more detailed descriptions of specific examples of components, features, and aspects of the invention are provided below.
A. General Overview of Example Finished Products
The upper member 102 of this illustrated example structure 100 further includes a closure system 108 to assist in holding the article of footwear 100 on a user's foot. While the closure system 108 in this example article of footwear 100 includes a conventional shoe lace and eyelet system, other closure systems may be used without departing from the invention, including, for example, known and/or conventional closure systems, such as hook-and-loop fasteners, straps, buckles, zippers, elastic bands or members, and the like.
The upper member 102 is attached to the sole structure 104 in this example structure. Any desired type of connection between the upper member 102 and the sole structure 104 may be used without departing from the invention, including conventional connections known and used in the art (such as adhesives, stitching, and the like). More specific examples of this connection for this illustrated footwear structure 100 will be described in more detail below in this specification. The sole structure 104 of this example, which also will be described in more detail below, includes an outsole member 110 for contacting the ground or other surface in use. As shown in
The junction between the upper member 102 and the sole structure 104 in this illustrated example structure 100 is covered by a foxing band 114. In this example structure 100, the foxing band 114 extends substantially around the entire perimeter of the shoe structure 100. The foxing band 114, which may be made from any desired number of independent pieces, may be of any desired width (including of a varying width), and it may be applied over and held to the upper member 102 and/or the sole structure 104 in any desired manner without departing from the invention, such as via adhesives, cements, stitching, or the like. The foxing band 114 may be formed of rubber (synthetic or natural), polymeric materials (such as thermoplastic polyurethane), or other desired materials. In this illustrated example structure 100, the free ends of the foxing band 114 are covered and held in place by an upwardly extending portion 116 of the sole structure 104, right at the rear heel area of the shoe structure 100. Of course, other ways of securing the foxing band 114 in place (when one is present) may be used without departing from this invention.
As shown in
The front portion of the foxing band 114 in this example footwear structure 100 extends around the front toe portion of the shoe 100, and it may provide additional wear resistance in this area. Additionally, the foxing band 114 of this illustrated example structure 100 extends over and at least partially helps secure a toe cap 118 over the front of the upper member 102. The toe cap 118 may be used to provide additional wear resistance in this front area of the shoe 100, which can be exposed to substantial bending, scraping, or scuffing forces in use. The toe cap 118 may be attached to the remainder of the footwear structure 100 in any desired manner and the foxing band 114 may be attached over a portion of the toe cap 118 in any desired manner, such as via adhesives, stitching, and the like.
As still another feature, if desired, the upper member material may have one or more discontinuities in it, like open regions 120 provided on one or both sides of the upper member 102 at the ankle area. These open regions 120 may be covered or filled with one or more layers of bootie material 122, as will be described in more detail below. Providing an opening or discontinuity in this ankle area can provide a more comfortable and/or dynamic fit, e.g., as compared with covering the ankle completely with upper member material (e.g., a generally stiff or unstretchable material that may cause irritation, undesirable folding or buckling, etc.).
Given this general overview of example footwear structures according to the invention, a more detailed description of various parts, components, and aspects of the invention follows.
B. Example Bootie Structures
The interior (or “foot-receiving chamber”) of articles of footwear or other foot-receiving devices can take on a wide variety of different constructions without departing from this invention. For example, if desired, in the example structure 100 shown in
Alternatively, in accordance with at least some examples of this invention, the foot-receiving chamber of the upper member 102 may have an interior member or “bootie” structure included therein. This bootie member may be made, for example, of a soft, comfort-enhancing material. This bootie member may comprise any desired number of pieces (e.g., separate pieces, pieces sewn or otherwise engaged together, etc.), and it may partially or completely fill the interior volume of the upper member 102.
The heel-containing region 206 of this example bootie blank structure 200 includes a lateral heel edge 206a extending in a direction from the rear end 210 toward the lateral side edge 212a such that the lateral heel edge 206a and the lateral side edge 212a extend and terminate proximate to one another (e.g., at a common point) and define edges to be engaged together when forming the bootie structure. Similarly, in this example structure 200, the heel-containing region 206 includes a medial heel edge 206b extending in a direction from the rear end 210 toward the medial side edge 214a such that the medial heel edge 206b and the medial side edge 214a extend and terminate proximate to one another (e.g., at a common point) and define edges to be engaged together when forming the bootie structure.
The bootie blank 200 of this example structure includes a second part, which may be on the same or a different physical material element from that including the first material element 202. As illustrated, this second part includes a tongue portion 220. A lateral edge 220a of the tongue portion 220 may be joined (e.g., by sewing) to at least a portion of a second lateral side edge 212b of the first material element 202, and/or a medial edge 220b of the tongue portion 220 may be joined (e.g., by sewing) to at least a portion of a second medial edge 214b of the first material element 202, to form the overall bootie structure. Additionally or alternatively, the front edge 220c of the tongue portion 220 may be joined (e.g., by sewing) to the front edge 222 of the first material element 202 when the overall bootie structure is formed. As still another alternative, if desired, the tongue portion 220 may be continuously formed with at least one portion of the first material element 202 (e.g., with the edges 212b, 214b, and/or 222) such that at least some of the sewing steps and/or seams can be eliminated.
If desired, at least one surface of the bootie materials 202 and/or 220 may include printed matter, and when the bootie is formed, this printed matter may be visible in the final footwear structure (e.g., as the bootie interior, through an opening provided in the upper member, etc.).
This example bootie blank 200 further includes additional patch elements 230, that may be used to provide a double layer of the bootie material over one or more openings 120 provided in the upper member 102, as shown in
Alternatively, as shown in the example bootie blank 450 of
The double layer of bootie material provided by extending portions 412, 414, and/or 456 can further enhance the comfort of the footwear (e.g., by providing soft, flexible, non-stiff material at these flexing and/or contacting points, e.g., as compared with the material of the upper member 102). Additionally, the presence of the bootie material at these locations can be more aesthetically pleasing when the materials flex during use (e.g., the material of the upper member 102 can be rather stiff and can tend to bunch up and/or fold up undesirably when flexed during use as compared with the bootie material).
The bootie blanks and the overall bootie structures may be made from any desired number of individual pieces and/or any desired types of materials without departing from the invention, including, for example, from conventional fabric and/or foam materials known and used in the art (such as knit fabrics, cotton fabrics, synthetic fabrics, polyurethane foams, etc.). In accordance with at least some examples of the invention, one or more layers of the material making up the bootie structure may be at least somewhat impermeable in at least one direction, e.g., to prevent or inhibit adhesives or other materials from passing from the exterior into the bootie interior. In accordance with at least some examples, the bootie may have an intermediate layer of soft flexible fabric material with one or more outer layers of batting or other at least somewhat impermeable material. In at least some examples, the bootie material will be breathable, to allow moisture, air, and/or heat to escape from the bootie interior. Alternatively, if desired, vent openings and/or other vent structures (such as eyelets, slits, slots, or other openings) may be provided in the bootie structure without departing from the invention.
C. Example Bootie/Upper Structures
Bootie structures 200, 400, and/or 450 of the types described above may be engaged with or contained in footwear upper members (and/or foot-covering members for other foot-receiving device products). As mentioned above, upper structures used in footwear (or foot-covering members for other foot-receiving devices) in accordance with this invention may take on a variety of different structures and constructions, and they may be made from a wide variety of materials (or combinations of materials) without departing from the invention, such as leathers, polymeric materials, fabric materials, canvas materials, and the like. The upper structure also may be made from any desired number of independent pieces of material without departing from the invention.
If desired, at this point in the construction, the bottom of the bootie element 502 (e.g., including the footbed or plantar surface) may remain relatively free and unattached, e.g., from the upper member 504. If desired, a heel counter element 506 may be attached to the heel area of the bootie member 502 (e.g., adhered directly to the exterior surface of the bootie member 502 via an adhesive, optionally with an intermediate foam or other impact-attenuating layer between the counter 506 and the bootie member 502, etc.). The heel counter element 506, when present, may be a thin element (e.g., made from thermoplastic polyurethane, plastic, or other suitable material having a relatively moderate stiffness (e.g., it remains relatively flexible)) that provides support for the heel and some structural rigidity to the overall footwear structure (e.g., particularly to the upper member 504 and bootie 502 when these members are made from relatively flexible materials, such as canvas and/or other fabrics), while still allowing the upper member 504 and footwear structure to conform to the wearer's foot.
The heel counter member 506, when present, may be directly bonded to the bootie member 502, e.g., via adhesive. In this manner, no additional structural elements are located between the heel counter 506 and the bootie member 502 (e.g., in many conventional athletic footwear structures, heel counters may be quite stiff and/or included as one layer in a multi-layer upper member structure). This feature enables the counter member 506 to have close contact with, and optionally wrap around, a portion of the wearer's foot. As illustrated in
As described above in conjunction with
D. Example Outsole Structures
Any outsole structure may be used on various articles of footwear without departing from this invention, and these outsoles may have any desired constructions, any desired tread design, and may be made from any desired materials without departing from the invention (including conventional constructions, tread designs, and materials known and used in the footwear art).
In at least some example outsole structures 600, as shown in
Additionally, if desired, one or more additional, non-herringbone or zig-zag areas may be provided as part of the sole structure 600 (e.g., areas 616 and 618 in
As mentioned above, the outsole member 600 may be constructed from any desired material(s) without departing from the invention, including from conventional materials known and used in the art. In at least some examples, at least the herringbone patterned portions of the first and second major surfaces 602 and 604 will be constructed from a flexible material, such as synthetic rubbers (e.g., of the types used in conventional basketball shoes, etc.). If desired, in at least some examples, the outsole member may include at least two different regions or portions, with at least one region or portion containing ridge and recess element portions and at least one region or portion not containing ridge and/or recess element portions (e.g., located around at least some portions of the perimeter of the ridge and recess containing portion(s), in the heel or toe areas, around the footwear outsole perimeter, etc.). In at least some example structures, these portions may have different thicknesses. For example, if desired, at least some of the ridge and recess element containing portions may be 1 to 2 mm thick (e.g., 1 to 1.5 mm thick in some examples), while at least some of the non-ridged and/or non-recessed portions of the outsole structure may be about 2-4 mm thick, and in some examples about 3 mm thick. In such structures 600, when the user steps down on the sole structure 600 (e.g., and applies a force having a component in a direction perpendicular to the second major surface, for example when changing directions, making a cut, landing a step or jump, etc.), at least some adjacent ridge elements 606 may splay outward somewhat under the force applied to the intermediate ridge element 610 by the foot, to thereby, in at least some arrangements, better grip the ground or other contact surface and provide better traction to the user. The differential thicknesses of the ridged and non-ridged portions of the outsole structure, in at least some examples, can positively contribute to this “splay” feature.
While any desired materials may be used for the outsole, in at least some examples, the rubber material of the outsole may be somewhat softer than some conventional outsole materials (e.g., 50-55 Shore A rubber may be used), to additionally help provide these splay/conformance characteristics. Optionally, if desired, a harder material may be used in the heel area and/or in the non-ridge and non-recess containing portions (e.g., by including an insert of 60-65 Shore A rubber around the perimeter of the heel or non-ridged portion(s)), which also can assist in providing the splay characteristics described above.
Other features of outsole members potentially available in accordance with at least some examples of the invention are illustrated in
In this illustrated example, the perimeter element 622 further includes a raised lateral edge portion 624 (e.g., at the lateral front and/or midfoot portion, at the lateral metatarsophalangeal area, near or slightly behind the lateral side toe area, etc.) extending substantially above other portions or areas of the perimeter element 622. This lateral edge portion 624 may be raised to a sufficient height (e.g., ¼ to 1 inch or higher) to help support, abut, prevent movement of, and/or contain the lateral side of the user's foot, (e.g., during a direction change, etc.). If desired, this lateral edge portion 622 may include a support member (such as a plastic or metal plate) embedded or otherwise formed therein, e.g., at area 626 as shown in
Of course, the outsole structure 600 may be formed as one piece or from multiple independent pieces joined together in any desired manner, including in conventional manners known and used in the art (e.g., via adhesives, fusing techniques, etc.), without departing from this invention.
E. Example Midsole Structures
Articles of footwear in accordance with at least some examples of this invention further may include a midsole member, e.g., provided between an outsole member and one or more of a bootie element, another midsole structure, a sock liner, an upper member, etc.
In at least some example structures 700, the base member 702 will include a moderator element 704 engaged therewith, e.g., adhered to an outer surface thereof, at least partially embedded therein, etc. In this illustrated example structure 700, the moderator element 704 is completely embedded within the base member (e.g., through a co-molding process). The moderator element 704 may have a thin plate or sheet like structure, e.g., made from reinforced plastics, thermoplastic polyurethane, fiberglass, or other suitable material (e.g., 30% glass fiber in nylon 66), and it may include first and second leg members 704a and 704b extending generally in a longitudinal direction of the base member 702 and a base portion 704c connecting the leg members 704a and 704b. Each leg member 704a and 704b includes a free end located at or toward the front portion of the base member 702, and each leg member 704a and 704b extends from its free end toward the base portion 704c located in or toward the rear (heel) portion of the base member 702. With this structure and construction, the moderator element 704 may allow at least some medial-lateral splay and conformance in the forefoot portion (e.g., due to the free ends of the moderator element 704), and it may create an appropriate flex point at the metatarsophalangeal or other joints, while still providing moderate and sufficient torsional rigidity and moderated deflection in the heel region (e.g., due to the stiffer and more structurally rigid base portion 704c).
Similar to the outsole structure 600 described above in conjunction with
In at least some example structures 700, the perimeter element 706 additionally will include an extending portion 708 at least along a portion of the lateral side of the base member 702 (e.g., at or near the fifth metatarsophalangeal joint or somewhat back from the smallest toe). If desired, an additional supporting element or structure (such as a plastic or metal plate) may be provided in this lateral side extending portion 708 of the perimeter element 706, e.g., so as to provide additional support and stability for the lateral side of the foot, for example, during direction changes, cutting actions, etc. This extending portion 708 may be provided to at least partially support, abut, contain, or otherwise engage the lateral side of the foot (e.g., at the fifth metatarsophalangeal area). This extending portion 708 may be any desired height, e.g., from ¼ to 1 inch high or higher, if desired.
At least some portions of the perimeter element 706, and particularly the extending portion 708, when present, may include one or more discontinuity regions 710 (e.g., along the lateral side of the base member 702, as part of the extending portion 708, etc.). These discontinuity regions 710, when present, may provide additional flexibility and allow the perimeter element 706 and/or the extending portion thereof 708 to better conform to the wearer's lateral foot area, e.g., during movement.
Additionally or alternatively, as also illustrated in
In situations (e.g., shoe designs, etc.) where additional midfoot support and torsion resistance and control are desired, a moderator element 704F of the type illustrated in
If desired, in accordance with at least some examples of the invention, midsole elements 700 of the types described above may be engaged on one surface with an outsole member, e.g., of the types described in conjunction with
F. Example Footwear and Foot-Receiving Device Construction Processes
Many ways of making articles of footwear or other foot-receiving device products including features and aspects of the invention may be used. The following describes some potential construction procedures that may be used in conjunction with the various individual parts described above (e.g., the bootie, upper member, outsole member, midsole member, etc.), e.g., for producing footwear structures of the types shown in
In general, a bootie blank 200 may be formed into a bootie member 300 or 502, optionally including a tongue portion 220, and joined to an upper member 504, e.g., in the manners described above in conjunction with
A heel counter 506 for additional heel and structural support may be attached to the bootie element 300 or 502, e.g., directly attached to the bootie element 300 or 502 using adhesives, and then the bootie element 300 or 502 may be attached to a midsole member 700, e.g., directly attached using adhesives. Direct attachment in these areas can be desirable, at least for some footwear structures, because direct attachment provides the impact-attenuation elements very close to the user's foot. Additionally, the resulting footwear structure may have a relatively low, close to the ground construction and feel that may be somewhat lower than many conventional athletic shoe sole structures. Some users may prefer or enjoy this low and close look and feel, at least for some activities.
Once the bootie element 300 or 502 is attached to the midsole 700, the upper member 504 (which was previously attached to the bootie element 300 or 502 and remained loose around its bottom portion as shown in
Once constructed, at least a portion of the bottom exterior of the midsole element 700 fits within the perimeter member 622 of the outsole element 600 such that the lateral extending edge portion 708 of the midsole element 700 also fits at least partially within and is supported by the lateral extending edge portion 624 of the outsole element 600 (see also
Of course, other structures, features, design elements, and the like may be included in the shoe structure, the order of the various construction steps may be changed, additional steps may be added, steps may be deleted, and the like, without departing from the invention. Also, additional design elements, such as patches, piping, logos, stickers, trim elements, laser trim, and the like may be provided at any suitable or desired time in the construction process without departing from this invention. At any suitable or desired time, when present, the openings 120 in the upper member structure 102 may be covered with additional material 122, such as an additional layer of bootie material 230 (e.g., by sewing, etc.), a patch member, etc., as described above.
G. Other Potential Features
Of course, articles of footwear and other foot-receiving devices may have a wide variety of features, constructions, and combinations of features and constructions without departing from this invention. For example, if necessary or desired, the upper member 102 and/or the bootie element 202 may include one or more vent structures (e.g., open eyelets, slits, slots, vanes, etc.), to enable increased breathability. As another example, if desired, as shown in
The present invention is described above and in the accompanying drawings with reference to a variety of example structures, features, elements, and combinations of structures, features, and elements. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims. For example, the various features and concepts described above in conjunction with
