Patent Grant
7647709
The present invention is directed to footwear, and more specifically toward footwear that includes a shank.
Boots and other footwear are typically constructed of materials that provide a comfortable, durable, and stable platform. Boots, such as hunting and hiking boots, are constructed with an upper connected to a sole assembly. The sole assembly has an outsole, a midsole, an insole, and an internal shank. Conventional boot construction provides a stable product, although additional stability typically results in a heavier product. It is desirable to maintain the durability and stability of a boot while reducing its weight.
The present invention overcomes limitations of the prior art and provides additional benefits. At least one embodiment of the invention includes a footwear assembly comprising a sole assembly connected to an upper. The sole assembly comprises a midsole made of a first material and having a forefoot portion, an arch portion, a heel portion, and a sidewall extending around a lateral side, a medial side and a heel side of the midsole. A stiffener is connected to the midsole. The stiffener is made of a second material stiffer than the first material. The stiffener has a base portion adjacent to the arch portion and at least one of the forefoot portion and the heel portion of the midsole. The stiffener has a side stabilizer and a heel wrap coupled to the base portion. The side stabilizer is adjacent to the sidewall in at least one of the arch portion and forefoot portion. The heel wrap is adjacent to the heel side and at least one of the lateral side and medial side of the midsole's sidewall. An outsole is connected to at least one of the midsole and the stiffener.
In another embodiment, an outsole is connected to at least one of the midsole and the stiffener. The midsole is made of a first material and has a plurality of lugs projecting away from the upper and defining recessed areas. A stiffener is connected to the midsole in at least some of the recessed areas. The stiffener has a plurality of apertures, and the plurality of lugs project through the apertures. The midsole has a forefoot portion, an arch portion, and a heel portion, and the stiffener is positioned in the arch portion and in at least one of the forefoot portions and the heel portions. An outsole is connected to the lugs.
A detailed description of the illustrated embodiments of the invention is presented below, which will permit one skilled in the relevant art to understand, make, and use aspects of the invention. One skilled in the relevant art can obtain a full appreciation of aspects of the invention from the subsequent detailed description, read together with the figures, and from the claims, which follow the detailed description.
A footwear assembly having a sole with an improved stiffener, such as a shank, is described in detail herein in accordance with embodiments of the present invention. In the following description, numerous specific details are discussed to provide a thorough and enabling description of embodiments of the invention. One skilled in the relevant art, however, will recognize that the invention can be practiced without one or more of the specific details. In other instances, well-known structures or operations are not shown or are not described in detail to avoid obscuring aspects of the invention. In general, alternatives and alternate embodiments described herein are substantially similar to the previously described embodiments, and common elements are identified by the same reference numbers.
As discussed in greater detail below, the shank 18 of the illustrated embodiment is at least a partially exposed shank (i.e., an external shank), although the shank in other embodiments can be covered by the outsole or other portions of the midsole assembly. As seen in
The lugs 30 in the midsole 16 of the illustrated embodiment are spaced apart to define a contoured recessed portion 32 formed in the midsole. The recessed portion 32 extends substantially the length of the midsole 16 from the forefoot portion through the arch portion to the heel portion. The midsole 16 of the illustrated embodiment also has an enlarged heel lug 34 positioned in a heel strike area. The enlarged heel lug 34 provides a thick portion of EVA for additional cushioning and shock absorption for absorbing forces, for example, during heel strike. The midsole 16 of the illustrated embodiment also has a plurality of molded channel portions 38 extending generally longitudinally adjacent to the medial and lateral side portions of the midsole. The channel portion 38 extends between the lugs 30 (in the forefoot and heel portions, respectively). Other embodiments can have the channel portions 38 formed in other areas of the midsole, such as the arch portion. The channel portions 38 can be recessed areas that receive portions of the external shank 18.
In one embodiment, the midsole 16 may be manufactured from a dual density material such that the outer exterior surface of the midsole, particularly along the sidewall, can be a more dense and durable material. The internal portions of the midsole 16 can be manufactured of a less dense material well suited for cushioning and shock absorption. The denser exterior surface of the midsole 16 can help provide for increased durability and wear resistance of the sole assembly 14.
As best seen in
In the illustrated embodiment, the outsole 20 does not cover the shank 18. In another embodiment, the outsole 20 is a substantially full-length outsole so that the shank 18 is not visible from the bottom of the boot, except perhaps for lateral and medial stabilizing portions of the shank that extend up along the sidewalls of the midsole at the arch portion, the forefoot portion, and/or the heel portion.
The shank 18 of the illustrated embodiment is a full-length external shank that extends under the forefoot, arch, and heel portions, 24, 26, and 28, respectively, of the midsole 16. The shank 18 of the embodiment of
In other embodiments, the shank 18 can be less than a full length stiffener. For example, the shank can be a three-quarter length stiffener. The shank 18 in other embodiments can extend through the arch area and through the forefoot area but not the heel area. In another embodiment, the shank 18 can extend through the heel area and the arch area, but not through the forefoot area. The shank 18 can be a unitary member or have components coupled together to provide the longitudinal and lateral stiffness desired while still allowing the midsole to flex and bend as needed throughout the wearer's gait.
The shank 18 of the illustrated embodiment is positioned within the recessed portion 32 formed in the midsole 16 between the lugs 30. The shank 18 of the illustrated embodiment is fixed to the midsole with an adhesive or other anchoring mechanism. Accordingly, the shank 18 of the illustrated embodiment is substantially fully exposed and is an external component of the sole assembly 14. As best seen in
The shank 18 of the illustrated embodiment has a forefoot section 44 integrally connected to an arch section of 46, which is connected to a heel section 48. The forefoot section 44 has a body portion with a pattern that provides lateral stiffness and stability while also allowing for longitudinal flexibility and bending, such as adjacent to the ball of the wearer's foot. The forefoot section 44 has stabilizing edge portion members 50 that wrap upwardly around sidewall/edge areas 52 of the midsole 16. The stabilizing members 50 are positioned with recesses 54 molded in the side wall of the midsole 16 adjacent to the edge area 52. Accordingly, the stabilizing members 50 of the shank's forefoot section 44 in the illustrated embodiment are exposed along the side of the midsole 16 to provide protection to the EVA and to provide visible material differentiation along the side of the sole assembly 14.
The shape and size of the stabilizing members 50 and the molded recesses 54 in the midsole 16 can be different shapes and sizes, particularly as may be desired, inter alia, for aesthetic and/or support reasons. In other embodiments, the stabilizing members can be configured to extend upwardly along the sidewall of the midsole and engage a portion of the shoe's upper adjacent to the midsole. The stabilizing members 50 on the medial and lateral sides can also be different sizes. For example, the stabilizing member on the lateral side (the outside) is taller or larger to provide increased stability to the outside of the wearer's foot. Other embodiments can have a larger stabilizing member of the medial side.
As best seen in
The arch section 46 of the shank 18 is positioned within the recessed portion 32 formed in the midsole 16 at the arch portion 26. The arch section 46 also has stabilizing edge portions or members 51 that wrap around the edges of the midsole and extend upwardly along molded recesses 62 formed in the midsole's sidewall at the arch portion. The arch section 46 in other embodiments can have stabilizing members 51 wrap upwardly along the sidewall of the midsole and along a portion of the shoe's upper. The stabilizing members of the arch section 46 can also be larger or taller to extend higher along the lateral side or the medial sides to provide a desired degree of stability for the user's foot. The size of the stabilizing members 51 on the medial and lateral sides of the arch section can be different depending upon the size of the forefoot sections 44 on the medial and lateral sides.
For example, stabilizing members of the arch section 46 and the forefoot section 44 of the shank on the lateral side can be larger or taller that the respective stabilizing members on the medial sides. Alternatively the stabilizing members 50 of the forefoot section can be larger on the medial side than on the lateral side (e.g., to provide better stability during the toe-off phase of a user's gait), and the stabilizing members 51 of the arch section can be larger or taller on the lateral side than on the medial side (e.g., to provide lateral stability during the transitions in a wearer's gait between heel strike and toe-off). Accordingly, the arch section 46, which is integrally connected to the forefoot section 44 and heel section 48, provides a stable arch support area in the sole assembly 14. In the illustrated embodiment, the arch section 46 has an aperture 64 therein that extends around a logo section molded into the midsole. Other embodiments do not include this aperture for the logo.
In other embodiments, the arch sections 46 of the shank 18 can be partially or fully covered with a portion of the outsole. The arch section 46 can be covered by a layer of resilient outer material that includes a plurality of protruding resilient grip members protruding from the arch area. The grip members of one embodiment are flexible rubber fin structures, although other shapes and materials can be used. The grip members provide additional traction in the arch area. For example, the grip members can provide traction when a wearer steps on a structure (e.g., a ladder rung, an edge of a sidewalk, etc.) in the arch area of the sole assembly. In other embodiments, the arch area of the shank can be provided with texture that can provide increased traction.
The heel section 48 of the shank 18 also has lateral and medial stabilizing edge portions or members 70 that fit within recessed areas 72 molded into the sidewalls of the midsole 16 along the heel portion 28. The heel section 48 of the shank of the illustrated embodiment has a plurality of apertures 74 that provide a degree of longitudinal flexibility of the external shank in the heel portion 28 while maintaining lateral stability. The stiffness characteristics can be different in other embodiments by providing a shank without the apertures or with larger apertures. The heel section 48 also includes protrusions 76 that fit within the channels 38 molded into the lateral and medial portions of the midsole 16 to facilitate the positioning and retention of the shank.
The heel wrap 22 in other embodiments can also wrap upwardly along the side of the midsole and along a portion of the shoe's upper around the heel area. The stabilizing members 70 of the heel wrap 22 can also be larger or extend higher along one side of the shoe (e.g., medial or lateral side) before it wraps around the heel area. For example, the heel wrap 22 can extend higher along the lateral side of the shoe than on the medial side to provide support and stability to the wearer's foot during heel strike. Accordingly, the heel wrap 22 can have an asymmetric configuration. The heel wrap 22 can also be contoured to accommodate the shape of a wearer's heel area for purposes of stability, comfort, and support.
In one embodiment, the shank 18 is formed of a translucent or a substantially transparent material (e.g., a TPU or plastic material). A pattern or image can be provided in or on the midsole so that the pattern or image is visible through the shank 18. In one embodiment, a camouflage pattern is provided on the midsole, so that the camouflage pattern is visible through the shank 18.
As best seen in
The sole assembly with the EVA midsole and the TPU shank 18 with the rubber outsole 20 provide a very durable and rugged boot having a very lightweight assembly without sacrificing the structural rigidity and performance of a hiking boot, hunting boot, or work boot.
The three materials used in the sole assembly 14 of the illustrated embodiment, namely the EVA, TPU, and the rubber of the outsole, can all have the same color (shown in the illustrated embodiment as being black). In other embodiments, the different materials can be different colors, for example, for aesthetic purposes. The materials for the midsole 16, the shank 18, and the outsole 20 can also have different textures to provide a visual difference in these components. Such visual differences can be appealing aesthetically for marketing and other purposes.
In another embodiment, the lugs 30 can be integrally formed in the outsole 20, and the outsole secured to the midsole 16 (
The midsole 102 has a generally flat bottom surface 110 adhered or otherwise secured to portions of the shank 106, and an upper surface 112 securely attached to the upper 104. The midsole 102 has a forefoot portion 114, an arch portion 116, and a heel portion 118. In the illustrated embodiment, sidewalls 120 of the midsole 102 have recesses 133 formed in each of the forefoot portion 114, the arch portion 116, and the heel portion 118. The recesses 133 are shaped and sized to receive portions of the shank 106, discussed in greater detail below. In other embodiments, recesses can be provided in only one or more of the forefoot, arch, and heel portions. In yet other embodiments, recesses need not be provided in the sidewalls 120.
The shank 106 of the illustrated embodiment has a forefoot portion 124 attached to the midsole's forefoot portion 114, an arch portion 126 attached to the midsole's arch portion 116, and a heel portion 128 attached to the midsole's heel portion 118. The shank 106 of the illustrated embodiment is a full-length shank formed of a stiff and substantially non-compressible material, such as TPU. Other materials, such as plastics, urethanes, polyurethanes, etc., could be used in other embodiments. Other embodiments can have ¾-length shanks, ½-length shanks, or other size shanks.
The outsole assembly 108 is shown as a two-piece outsole with a forward section 108A and a rear section 108B. The forward section is attached to the forefoot portion 124 of the shank and extends forwardly from the arch portion 126 through the forefoot portion. The rear section 108B is attached to the heel portion 128 of the shank and extends rearwardly from the arch portion 126 through the heel portion. Accordingly, the arch portion of the shank in the illustrated embodiment is exposed. In other embodiments, the front and rear sections 108A and 108B can be connected together by outsole material that can partially cover parts of the shank's arch portion. In another embodiment, the outsole can be a full-length outsole that covers the shank from heel to toe. In another embodiment, portions of the shank's forefoot portion 124 and/or heel portion 128 can be exposed.
The outsole assembly 108 of the illustrated embodiment is constructed with a tread pattern that can include lugs or other tread features. Portions of the forward and/or rear sections are constructed with a transparent or translucent outsole material. For example, the transparent or translucent material, such as durable rubber, can be provided between the tread features. Accordingly, portions of the shank can be seen through the transparent or translucent material. The shank can be provided with designs, patterns, text, camouflage, logos, colors, or other visual images that can be seen through the outsole. In other embodiments, the outsole can be made of opaque material.
In the illustrated embodiment, the shank includes the stabilizing members 50 at the forefoot portion, stabilizing members 51 at the arch portion, and the heel wrap 22 at the heel portion as discussed above. The shank in other embodiments can have other configurations or combinations of the stabilizing members and/or the heel wrap. For example, in one embodiment, the shank has the stabilizing members in the arch portion and the heel wrap, but not the forefoot stabilizing members. In another embodiment, the shank only has the heel wrap 22. In yet other embodiments the shank only has the forefoot stabilizing members.
From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
This application claims priority to provisional U.S. patent application Ser. No. 60/682,923, entitled FOOTWEAR WITH EXTERNAL SHANK, filed May 19, 2005, and which is incorporated herein by reference thereto.
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