Patent Grant
7984569
This invention relates to a modular system for an item of footwear (e.g., shoes, boots, sandals, slippers). In particular, the system provides removable modular sole components that allow customization of an item of footwear with respect to traction, cushioning, support, fit, performance and/or aesthetic functions and features.
Footwear having replaceable sole unit receivers are known in the prior art. One such footwear item, which is particularly adapted for use by fishermen, footwear is disclosed in U.S. Pat. No. 6,813,847 and in pending US Publication No. US2006/0042119, the contents of which are hereby incorporated by reference in their entireties. The footwear disclosed in that patent includes a cavity in its sole that removably receives a sole plate having a tread pattern on its lower surface.
The inventive subject matter disclosed herein contemplates a sole unit and/or sole unit receiver, which combine to form a sole assembly, that have one or more of the following features alone or in combinations:
In one possible embodiment, the inventive subject matter contemplates a sole unit with one or more engageable elements, the sole unit and engageable elements being adapted to be received by a sole unit receiver for an item of footwear to form a sole assembly, the one or more engageable elements each having a corresponding engageable element on the sole unit receiver to form a male-female pair of elements that provide an interference fit that helps secure the sole unit to the sole unit receiver relative to forces that may act generally parallel to the ground facing surface of the sole unit.
In another possible embodiment, a sole unit that is adapted to be received in a sole unit receiver, the sole unit including at least one portion of a surface with a plurality of teeth adapted to engage a set of teeth on a sole unit receiver. (Hereinafter, the term “teeth” shall broadly refer to teeth and similar alternating structures that may be engaged with complementary alternating structures.)
A sole unit having an intermediate waist portion and opposing portions on either side of the intermediate portion that are wider than the intermediate portion, the sole unit being receivable in sole unit receiver having complementary opposing portions and an intermediate waist portion so that the interference of the opposing portions in the sole unit against the complementary waist portion in the sole unit receiver results in a bidirectional stop.
A method of making an item of footwear comprising, providing a sole unit with one or more engageable elements, each having a corresponding engageable element on a sole unit receiver to form a male-female pair of elements that provide an interference fit that helps secure the sole unit to the sole unit receiver relative to forces that may act generally parallel to the ground facing surface of the sole unit; and providing the sole unit receiver so that a sole assembly in engaged or disengaged form is together.
In these and other embodiments:
The sole unit may have an interference fit that is in the nature of a bidirectional stop that helps secure the sole unit against forces that act generally along at least a long axis of the sole unit.
In the sole assembly, one of the pair of engageable elements of the sole assembly may be a male part having an elongate portion that is generally oriented perpendicularly to the ground facing surface of the sole assembly. In the sole assembly, the male part may be disposed in a midfoot portion of the sole unit, spaced between lateral and medial sides of the sole unit.
In the sole assembly, one of the pair of engageable elements of the sole assembly may be a male part having an elongate portion that is generally oriented perpendicularly to the long axis of the sole assembly and extends into a sidewall of the sole unit or sole unit receiver.
In the sole assembly, the elongate element may comprise a threaded element.
In the sole assembly, the end of the male part that engages the complementary female part may terminate in a shape that has an outwardly extending horizontal component, such as a hook mushroom, or tear-dropped shaped head.
In the sole assembly, the sole unit may further include an engageable element that allows for coupling of the sole unit to the sole unit receiver by a rotational action of one of the complementary elements.
In the sole assembly, a male engageable element may include a hand tool for engaging or disengaging the elements.
In the sole assembly, the sole unit may include an engageable element in a midfoot portion spaced between lateral and medial sides of the sole unit.
In the sole assembly, the sole unit may have first and second sets of alternating structures, such as teeth, disposed on opposing surfaces of a portion of the sole unit, each set of alternating structures are adapted to engage a set of alternating structures on the sole unit receiver.
The sole unit may include a surface that is adapted to be received in a sole unit receiver, the surface including a surface with a texture or pattern adapted to frictionally engage a surface on a sole unit receiver.
In the sole assembly, the sole unit may have a three dimensional conformation and be adapted to be received in a sole unit receiver having a complementary conformation.
In the sole assembly, the sole unit may further include a cushioning element or a receiver for a cushioning element discretely disposed on at least a portion of a forefoot or a portion of a rearfoot area of the sole unit.
In the sole assembly, the sole unit and/or sole unit receiver may be adapted to address pronation or supination.
In the sole assembly, the sole unit may include a felt or studded outsole portion.
The sole unit may include a reinforcement material comprising a fiber, filament or fabric. The reinforcement may be included in a base layer of the sole unit.
In another possible embodiment, a hand key configured with a portion for gripping and an opposite portion with a size and shape that allows for manipulation of an engageable element in a sole unit assembly for assisting in flexing apart the engageable element so it may be more open to receive its complementary engageable element, the hand key provided in a kit, the kit comprising the hand key and an item of footwear with a sole assembly, according to the inventive subject matter, or a sole unit alone.
Methods of making any of the sole units, sole unit receivers, and/or items of footwear incorporating any of the same are also contemplated.
The inventive subject matter also contemplates a hand key configured with male or female parts for engaging the opposite kind of part on a sole assembly.
All other novel embodiments and combinations of components or features shown and described herein.
The foregoing is not intended to be an exhaustive list of embodiments and features of the present inventive concept. Persons skilled in the art are capable of appreciating other embodiments and features from the following detailed description in conjunction with the drawings.
In broad terms, the inventive subject matter herein relates to a sole unit that is engageable to a sole unit receiver by various novel engagement systems. The combination of a sole unit and sole unit receiver (which hereinafter may be referred to as a “sole assembly”) provides foot supporting and ground engaging functions, as well as other functionality, that sole systems are known to provide, such as cushioning, support, fit, performance and/or aesthetic functions. While sole assemblies generally extend the length and width of a foot, a sole assembly could also consist of an assembly that provides a smaller area of coverage such as coverage just under a forefoot (e.g.
The functions generally provided by a sole assembly may be distributed across the assembly of sole unit and sole unit receiver in most any fashion. For example, the sole unit could be adapted to include just a traction surface, such as a rubber outsole, and the sole unit receiver could be adapted to provide the primary cushioning functionality, for example by it being in the form of a foamed EVA material. Alternatively, the sole unit could include cushioning materials or elements, e.g., 101,
Referring to
As used herein, “footwear” refers to any item for supporting the foot and engaging the ground and encompasses shoes, sandals, boots, slippers, over shoes, athletic shoes, and other footwear articles. “Cushioning elements” refers to basic shock absorbing, energy return, and/or protective underfoot materials or structures that are intended to react to the forces of foot strike by providing force attenuation, dissipation, dampening, or energy return (spring), which are typically included on sports and athletic shoes. Traditionally, a cushioning element comprised a consistent and uniform layer of shock absorbing and protective material, such as such as EVA or polyurethane, placed in a shoe between the foot and the ground. However, in relatively recent years there has been trend towards customized placements of varying cushioning materials and structures under a foot. Nowadays, common cushioning elements may be based on EVA or polyurethane foam, visco-elastomers of foam or gels, fluid filled bladders, mechanical springs or resiliently collapsible mechanical structures, fluid (e.g., air) springs, or any combination of the foregoing.
For example polymer spring units have been placed in portions in the sole unit receiver, particularly the heel portion, and in some cases the forefoot portion. Mechanical polymer springs may be formed from an injected thermoplastic, such as Hytrel polymer, PEBAX, and TPU, as well as other resilient polymers, thermo-set plastics, and metallic materials known in the art, alone or in combination. See, for example, U.S. Pat. No. 5,461,800, which is hereby incorporated by reference in its entirety. The U.S. Pat. No. 5,461,800 discloses a foamless midsole unit, comprising upper and lower plates sandwiching transverse cylindrical units formed of resilient polymer See also, for example, U.S. Pat. Nos. 4,910,884, 6,625,905, and 5,337,492. Other forms of mechanical springs, such as leaf-spring structures are also contemplated.
A sole unit 26 or sole unit receiver 12 may include cushioning elements in accordance with any of the foregoing cushioning elements. Contemplated fabrication methods for the sole assembly and any associated cushioning elements include molding, injection molding, direct-injection molding, one-time molding, composite molding, insert molding, co-molding separate materials, or other techniques known in the art, alone or in combination. Contemplated fabrication or assembly methods include adhesives, bonding agents, welding, mechanical bonding, die cutting of molded or other materials, or interlocking shapes, alone or in combination. Laminated structures are within the scope of the present invention.
Dampening elements, which are a form of cushioning element (as defined herein), may also be incorporated into the sole units and/or sole unit receivers disclosed herein. “Dampening” generally refers to the ability of certain materials to reduce the amplitude of oscillations, vibrations, or waves. In footwear, shock from impact may generate compression waves or other vibrations within the sole system. Contemplated dampening materials include visco-elastomers. In some instances, plain elastomer materials may be used as dampeners; however, they may not provide as desirable dampening qualities on the spring unit as a visco-elastomer. Example materials for a visco-elastic dampener include any number of polymers, including polyurethanes and polyethylenes in foam or gel form, fabricated by conventional molding practices or by film. Other suitable visco-elastomers are known to persons skilled in the art. Contemplated fabrication methods for visco-elastomers include molding, injection molding, direct-injection molding, one-time molding, composite molding, insert molding, co-molding separate materials, or other techniques known in the art, alone or in combination. Contemplated fabrication or assembly methods include adhesives, bonding agents, welding, mechanical bonding, or other mechanical or chemical fastening means know to persons in the art, alone or in combination. Laminated dampener structures are within the scope of the present invention.
The outsole or traction surface for a sole assembly may include rubber, leather, cleats, spikes, studs, shanks of metal or other rigid material, felts, EVA, foam, and other cushioning technologies, and combinations of the foregoing.
The sole unit 26 and sole unit receiver 12 may be releasably engaged to each other by various configurations of male-female interconnections and/or interference-fit arrangements (hereinafter such elements may be referred to as “engageable elements”). Generally, the various pairs of engageable elements may be distributed across a sole assembly in any manner or number provided that they reasonably securely engage the sole and sole unit receiver together for purposes of an intended use of an item of footwear. For example, all male parts could be disposed on the sole unit and all female parts could be disposed on the sole unit receiver, or vice versa. Or the sole unit or the sole unit receiver could each have a set of male-female parts that engage corresponding parts on the other of the sole unit or sole unit receiver. The following embodiments illustrate just some of many possible arrangements of releasably interconnecting elements.
A sole unit 26 is generally sized to fit within and substantially fill the cavity 14. The sole unit may have the same thickness as the thickness of the sidewall so that the sole unit and sole unit receiver have a flush surface for purpose of ground contact. The sole unit may also be designed in whole or part to vary in elevation from the sole unit receiver. For example, a heel portion may be raised to provide a boot heel or a central portion might be recessed to provide certain cushioning functionality that is based on the greater collapsibility of the relatively raised perimeter to the recessed central portion.
As noted above, the sole unit may be made from any single or combination of materials used or usable in the construction of soles. These materials include rubbers, foams, elastomers, visco-elastomers, plastics, natural and synthetic leathers, textiles, woods, fibers and metals. In a simple construction, the sole unit may have a flexibility that is similar to that of the sole unit receiver 12. However, the sole unit may be replaced with another construction to provide greater or lesser flexibility, according to the demands of a particular user or intended use. The sole unit may also be replaced with another construction to provide customized support functions. For example, a sole unit may be provided with more support on a medial side to help a runner whose foot pronates. Likewise a sole unit may be provided with more support on a lateral side to compensate for a runner whose foot supinates. Additionally, the sole unit could be constructed with a material that provides resistance to environmental conditions such as sharp objects or corrosive chemicals for safety in work places where such conditions may be present.
Turning now to one possible embodiment illustrating how a sole unit releasably engages the sole unit receiver, a thin tab 28 may be located at any portion along the sole unit for engagement with a complementary slot in the sole unit receiver. For example, as illustrated in Figures, tab 28 is disposed on the toe end of the sole unit 26 and fits into the slot 20 when the sole unit is inserted into the cavity.
A sole unit may be a unitary structure (e.g., molded unit) or it may be composed of two or more subcomponents combined together as a single unit (e.g. by adhesives or fasteners). For example, the tab 28 may be an extension of a thin base layer 30 which forms the upper portion of the sole unit and supports a midsole and/or outsole structure, for example.
The base layer generally will have sufficient flexibility to accommodate normal foot flexion for a specific use. For example, dance shoes typically allow more flexion than hiking or work boots. In one possible embodiment where the sole unit consists of the base layer and a flexible outsole material, the base layer is substantially less flexible than the remainder of the sole unit so as to have a sufficient combination of stiffness and resilience to facilitate the placement of the sole unit in the sole unit receiver, while allowing for desired flexion, as described in more detail below. In one possible embodiment the outsole material is glued to the base layer, but it could be joined by other means, such as fasteners or co-molding. Alternatively, there could be no specific base plate
The base layer or other sole unit construction may also support other elements, such as a cushioning element 101 on the same or an opposite surface. The base layer, as well as other sole assembly components may be made from various plastic or rubber materials, such as ABS, Hytrel, Pebax, PVC, polyurethanes, Nylons, including Nylon 6 and Nylon 12, thermoplastic urethanes, EVA, carbon and glass fiber composites, rubbers, spring metals, etc. The base layer as a distinct component is optional and a single unit may be formed or constructed that provides multiple sole unit functions in a monolithic structure. For example, this could be achieved by known co-molding or over-molding processes where materials of different material properties or structures are joined together. In such constructions, the tab 28 could be integral with the rest of the sole unit.
In one possible embodiment, the sole unit includes a base layer with reinforcing glass fibers, filaments, or fabric molded into the layer. In one possible embodiment, the base layer is Nylon 6 and incorporates about 5% glass fiber. In certain embodiments, the base plate is constructed to flex with the sole unit receiver but is stiffer than the general receiver, and any midsole, for better retention in the receiver.
Sole units may also be provided that have flexural lines that correspond to the lines of flex in a foot.
Looking at
The flaps 22 may be elastically deformable or flexible enough to be deflected upwardly to allow the portions of the base layer located above the depressions 38 to be snapped in place above the flaps when the sole unit is inserted into the cavity. However, the flaps are sufficiently stiff to hold the sole unit in place once the base layer is pushed past the flaps. In the embodiment illustrated, the bottom edges 56 of the flaps 22, and the top edges 58 of the portions of the base layer 30 located above the depressions 38 are rounded to facilitate pushing the base layer past the flaps. The flaps are somewhat harder than the remainder of the sidewall. For example, the flaps may have a hardness of between 90 and 95 Shore A Durometer and the remainder of the sidewall may have a hardness of between 80 and 85 Shore A Durometer. These numbers are intended to be example Durometers, and Durometers of varying degree may be appropriate, depending on the specific application to be pursued. The engageable elements in a pair of complementary engageable elements may have the same or different Durometer. In some cases variations in Durometer could facilitate an interlocking fit of one element to another. For example, a male element may have a higher Durometer so as to achieve a compression fit with a female part of lower Durometer, or vice versa.
In certain embodiments, as shown in
To increase the surface area of outsole against the ground, the perimeter of the sole assembly may include selectively placed male-female engageable elements.
Looking at
The sole assembly may be configured three-dimensionally to conform to a heel, a forefoot, and/or side foot portions. For example, while the use of the interlocking tab 28 and slot 20 at the toe end, the strap 32 and hook 36 at the heel end and the flaps 22 in between all prevent the sole unit from being pulled out of the footwear perpendicular to the sole unit, if the sole unit is strongly urged rearwardly it might pull free. To help prevent this, the top surface 46 of the cavity has an indented portion and the sole unit 26 has a projecting portion which interacts with the indented portion to prevent movement of the sole unit relative to the sole unit receiver longitudinally along the footwear without first lifting the sole unit perpendicularly out of the cavity. In the embodiment shown in
In the embodiments of
In this and other embodiments, there may be a reversal of the male-female parts. In other words, the sole unit 26 may have the opening that mates with a protrusion in the sole unit receiver 14. As used herein, complementary means geometrically shaped and sized for snug interconnection, or a male or female part that is not so shaped and sized but has material properties such that it will conform to a male or female part to which it is being interconnected.
In the foregoing and other embodiments disclosed herein, the male and female parts may be on any one of or both of the sole unit and sole unit receiver. They may be formed with any of the materials used to make a sole unit or sole unit receiver. Some strengthening of the materials might be desirable to provide for durable engageable elements. For example, if the female part is formed in midsole EVA of a sole unit receiver, a relatively higher durometer might be used for this part.
While the embodiments show the waist in the midfoot and the opposing sections in the forefoot and rearfoot, the concept may be applied in any region of the sole unit receiver. For example, as illustrated in
To facilitate the releasability or attachability of the sole unit to the sole unit receiver, one or more hand tools may be provided in the sole assembly. The hand tool generally is a structure or structures that are disposed on the sole assembly and can be pulled, pushed, turned or otherwise manipulated to cause the sole unit and sole unit receiver to engage or disengage. The hand tool may be located any place on the sole unit, but normally it would be placed in a manner that is not subject to wear and tear and does not interfere the performance or comfort of a shoe. Accordingly it may be placed on a side, heel or front of a shoe, and it interfaces where a sole unit and sole unit receiver join together. It may also be recessed in the bottom of a sole assembly. An example of a hand tool is shown in
In addition to hand tools on or in the sole assembly, the inventive subject matter also contemplates a separate hand key that may be used to assist in engaging or disengaging the sole unit and sole unit receiver from one another. For example,
In one possible embodiment, after the sole unit is placed in the cavity, the strap's opening 34 is placed over the hook 36. If the strap 32 has elasticity, the elasticity may help hold the rear end of the sole unit on the footwear. In another possible embodiment, the hand tool may connect to the sole unit receiver between the sole unit and the sole unit receiver so that pulling the strap pops out the sole unit in a manner similar to which batteries can be popped out of a battery compartment by a strap in some consumer electronic devices. In other embodiments the hand tool may be a rigid lever or a pull ring on an elongate member, for example.
A hand tool that extends from the sole assembly to a side portion of a shoe is not the only contemplated arrangement. The hand tool could also be tucked into a cavity, recess, hole, notch, slot, etc. and have an end exposed for hand manipulation.
Notably, it can be seen that in these embodiments the hand tools are also bidirectional stops that limit movement of the sole unit relative to the sole unit receiver. In the threaded versions, the sole unit not only limited from moving parallel to the bottom surface of the shoe, but also perpendicularly from the bottom.
As shown in
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of this inventive concept and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein.
All patent and non-patent literature cited within this application is hereby incorporated by reference as if included in its entirety.
Under 35 U.S.C. 119(e), this application claims the benefit of and priority to U.S. provisional patent application No. 60/800,535, filed May 12, 2006, which is hereby incorporated by reference as if listed in its entirety for all purposes. Under 35 U.S.C. 120, this application also is a Continuation in Part claiming the benefit of and priority to U.S. non-provisional patent application Ser. No. 10/925,605, filed Aug. 24, 2004, which is hereby incorporated by reference as if listed in its entirety for all purposes.
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