A. Field of the Invention
The present invention relates to the manufacture and development of shoe soles and insoles that are composed of layers of different types and densities of materials.
B. Description of the Related Art
As physical activity becomes more important in our society's struggle with obesity, there is a need to establish new ways of motivating physical activity. And, as individuals become more physically active to become healthy, the materials that they use will need to be replaced more frequently. For example, a shoe is manufactured with only so much tread and material on the sole and insole, and therefore must be replaced after that tread or material has worn away. As avid runners can attest, sneakers or running shoes need to be replaced after a certain amount of use to maintain optimal performance and to prevent injury. This invention addresses a need to understand how much wear and use a shoe sole or insole has endured.
The present invention provides footwear systems, footwear sole systems, and methods of making footwear systems and footwear sole systems that overcome deficiencies in the art. Specifically, the systems provide an easy and simple means of measuring the wear of footwear and of providing other information, such as motivational messages, to a user of the footwear.
Footwear sole systems of the invention comprise a sole having two or more layers wherein a first sole layer has an outer bottom surface configured to contact a ground surface and an inner upper surface bonded to a bottommost surface of an inner sole layer and a second sole layer has a top surface configured to contact the bottom surface of a first insole layer and a bottom inner surface bonded to a topmost surface of an inner sole layer, wherein an inner sole layer is molded in a manner able to convey information when the bottom surface of the inner sole layer is exposed by degradation of the first sole layer; and an insole having two or more layers wherein the first insole layer has a top surface bonded to a bottommost surface of an inner insole layer, and a second insole layer has a top surface configured to contact a user's foot and bottom surface bonded to a topmost surface of an inner insole layer, wherein the topmost inner insole layer is molded in a manner such that information is conveyed to the user when the second insole layer is degraded by friction to expose the inner insole layer.
In some embodiments of footwear sole systems of the invention it is expected that there will be two or more inner sole layers present. In these systems, the upper and lower surfaces of the inner sole layers that are not in contact with either a first sole layer or a second sole layer will be in contact with an upper or lower surface of another inner sole layer. The upper and lower surfaces of inner sole layers that are in contact with each other are bonded to each other.
In some instances the inner sole layer and the second sole layer are the same layer.
Certain embodiments of footwear sole systems of the invention provide that there will be two or more inner insole layers present. In these systems, the upper and lower surfaces of the inner insole layers that are not in contact with either a first ininsole layer or a second sole layer will be in contact with an upper or lower surface of another inner insole layer. The upper and lower surfaces of inner insole layers that are in contact with each other are bonded to each other.
In some instances the inner insole layer and the first insole layer are the same layer.
Optionally, the first sole layer and inner sole layer(s) may have the same or different thicknesses or densities. Similarly, the first insole layer and inner insole layer(s) may have the same or different thicknesses or densities. It is envisioned that all layers of both the sole and insole may comprise either the same or different colors, textures, and types of materials. The selected makeup of materials, textures, thicknesses, densities, and other characteristics of any layer comprising a sole or insole of the invention is determined by the desired rate of degradation of a targeted layer. This rate of degradation will in part be determined by the type of information that it is desirable to convey to the user. For example, it may be desirable to convey a motivational message to encourage further physical activity more quickly than a message designed to indicate the amount of wear of a shoe. In the first instance, the composition of the layer to be degraded will be designed to cause a more rapid degradation than the rate of degradation of the target layer in the second instance.
The invention also provides for footwear systems that comprise a sole of a shoe. Such soles may be combined with an insole of the invention or another insole. Such a footwear system comprises a sole having two or more layers wherein a first layer has an outer bottom surface configured to contact a ground surface and an inner surface bonded to a bottommost surface of an inner layer, or a bottom surface of a second layer, or a combination thereof, wherein the second layer has an outer upper surface configured to contact the bottommost surface of an insole. And, the inner layer is molded in a manner able to convey information to a user when the bottom surface of the inner layer is exposed by degradation of the first layer. Further, the first layer of the first component is designed to degrade by friction at a controlled rate such that the inner layer is exposed after a desired amount of use of a shoe. Preferably, friction is generated by contact with the ground.
In some configurations of the invention, the inner layer of the sole is also the second layer of the sole.
The invention further provides for footwear systems that comprise an insole of a shoe. Such insoles may be combined with a sole of the invention or another sole. Such a footwear system comprises insole having two or more layers wherein a first layer has an outer upper surface configured to contact a foot and an inner bottom surface bonded to as uppermost surface of an inner layer, or an upper surface of a second layer, or a combination thereof, wherein the second layer has an outer bottom surface configured to contact the topmost surface of a sole, wherein the inner layer is molded in a manner able to convey information to a user when the upper surface of the inner layer is exposed by degradation of the first layer. The first layer of the insole is designed to degrade at a controlled rate by friction such that the inner layer is exposed after a desired amount of use of a shoe. Preferably, friction is generated by contact with the ground.
In some configurations of the invention, the inner layer of the insole is also the second layer of the insole.
Footwear systems of the invention also comprise a first component having two or more layers wherein a first layer has an outer bottom surface configured to contact a ground surface and an inner surface bonded to a bottommost surface of an inner layer, or a bottom surface of a second layer, or a combination thereof, wherein the second layer has an outer upper surface configured to contact the bottommost surface of a second component, wherein the inner layer is molded in a manner able to convey information to a user when the bottom surface of the inner layer is exposed by degradation of the first layer. The first layer of the first component is designed to degrade by friction at a controlled rate such that the inner layer is exposed after a desired amount of use of a shoe. Preferably, friction is generated by contact with the ground.
In some configurations of the invention, the inner layer of the first component is also the second layer of the first component.
The second component of footwear systems of the invention has two or more layers wherein a first layer has an outer upper surface configured to contact a foot and an inner bottom surface bonded to as uppermost surface of an inner layer, or an upper surface of a second layer, or a combination thereof, wherein the second layer has an outer bottom surface configured to contact the topmost surface of the first component, wherein the inner layer is molded in a manner able to convey information to a user when the upper surface of the inner layer is exposed by degradation of the first layer. The first layer of the second component is designed to degrade at a controlled rate by friction such that the inner layer is exposed after a desired amount of use of a shoe.
In footwear systems comprising a first component that contacts a ground surface and second component that contacts a foot, the first component is a sole, and the second component is an insole.
Footwear systems of the invention also comprise a first component having two or more layers wherein a first layer has an outer upper surface configured to contact a foot and an inner bottom surface bonded to an uppermost surface of an inner layer, or an upper surface of a second layer, or a combination thereof, wherein the second layer has an outer bottom surface configured to contact the topmost surface of a second component, wherein the inner layer is molded in a manner able to convey information to a user when the upper surface of the inner layer is exposed by degradation of the first layer. The first layer is designed to degrade at a controlled rate by friction such that the inner layer is exposed after a desired amount of use of a shoe. Preferably, friction is generated by contact with the foot.
In some configurations of the invention, the inner layer of the first component is also the second layer of the first component.
The second component of footwear systems of the invention also has two or more layers wherein a first layer has an outer bottom surface configured to contact a ground surface and an inner surface bonded to a bottommost surface of an inner layer, or a bottom surface of a second layer, or a combination thereof, wherein the second layer has an outer upper surface configured to contact the bottommost surface of the first component, wherein the inner layer is molded in a manner able to convey information to a user when the bottom surface of the inner layer is exposed by degradation of the first layer. The first layer of the second component is designed to degrade at a controlled rate by friction such that the inner layer is exposed after a desired amount of use of a shoe.
In footwear systems comprising a first component that contacts a foot and second component that contacts a ground surface, the first component is an insole, and the second component is a sole.
The invention also provides methods of making the claimed footwear sole systems. A first method of the invention comprises the steps of making a sole having multiple layers by pouring a first liquid into a first mold and allowing the first liquid to form a first layer, adding a second liquid on top of the first layer and allowing the second liquid to form a second layer that bonds to the first layer, wherein the first layer is allowed to solidify sufficiently prior the addition of further material to prevent disruptive admixing between layers; making an insole having multiple layers by pouring a first liquid into a second mold and allowing the first liquid to form a first layer, adding a second liquid on top of the first layer and allowing the second liquid to form a second layer that bonds to the first layer, wherein the first layer is allowed to solidify sufficiently prior the addition of further material to prevent disruptive admixing between layers; and combining the solidified sole with the solidified insole to form the footwear sole system.
Some methods of making footwear sole systems of the invention comprise the addition of one or more additional layers to the sole by repeating the steps used to form the first and second sole layers. Similarly, some methods of making footwear sole systems of the invention comprise the addition of one or more additional layers to the insole by repeating the steps used to form the first and second insole layers.
In some embodiments, the methods of making footwear sole systems of the invention further comprise placing one or more removable molds on top of the first sole layer such that one or more portions of the first sole layer are covered and the second liquid cannot bond to the first layer in the covered areas. It is expected that removable molds may be in the shape of a graphic, symbol, text, or combination thereof such that upon degradation of the target sole layer, the desired information can be conveyed by the pattern caused by the removable mold(s).
Similarly, the methods of making footwear sole systems of the invention may further comprise placing one or more removable molds on top of the first insole layer such that one or more portions of the first insole layer are covered and the second liquid cannot bond to the first layer in the covered areas. The removable molds may be in the shape of a graphic, symbol, text, or combination thereof such that upon degradation of the target sole layer, the desired information can be conveyed by the pattern caused by the removable mold(s).
Another method of making the footwear sole systems of the invention comprises the use of a pressure mold in combination with heat, adhesive(s), or another appropriate bonding agent(s). The method comprises the steps of making a sole having multiple layers by placing a first preformed sole layer and a second preformed sole layer in a pressure mold; adding heat or adhesive to the pressure mold and operating the pressure mold to press the first preformed sole layer and second preformed sole layer together with sufficient pressure to bond the first and second preformed sole layers to each other; making an insole having multiple layers by placing a first preformed insole layer and a second preformed insole layer in a pressure mold; adding heat or adhesive to the pressure mold and operating the pressure mold to press the first preformed insole layer and second preformed insole layer together with sufficient pressure to bond the first and second preformed insole layers to each other; and combining the pressed sole with the pressed insole to form the footwear sole system. Additional sole layers and insole layers may be added by repeating the described, appropriate steps.
Herein, the terms sneaker, running shoe, athletic shoe, and the like are used interchangeably to refer to footwear or shoes. The invention is not limited to use in sneakers, running shoes, or athletic shoes. The invention is suitable for use in any type of footwear for which it is desirable to track or measure the wear or degradation of the sole or insole.
The manufacture of shoes using rubber, rubber-like, plastics, and other materials are well known in the art. It is expected that manufacture of the present invention can be accomplished by adapting present manufacturing techniques to use the modifications exemplified herein without undue experimentation.
Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.
The invention provides a sole and an insole for a shoe. Both the sole and insole are made of multiple layers that wear or degrade at different rates such that wear patterns can be discerned. The wear patterns provide different types of information to a user. For example, a motivational message or graphic may be revealed by wear, or the wear pattern may indicate that footwear needs to be replaced. By developing the shoe sole and insole in layers of material having different densities and thicknesses, a different layer of information/color/feedback can be exposed as material is worn away at different rates.
The present invention also relates to the manufacture and development of shoe soles and insoles. More specifically, the invention relates to the manufacture and development of soles and insoles that are composed of layers of materials. Preferably, the soles and insoles of the invention are composed of different types and densities of materials. The material of the shoe is manufactured in layers of color, graphics, etc. to provide subsequent feedback to an owner, runner, shoe user, etc.
As the sole and insole of the shoe encounters friction, the makeup of the sole and insole changes due to the wearing away of material. This degradation of the sole and insole provides an indication of the portion(s) that have endured the most and least wear. The invention takes advantage of this pattern of wear or degradation to communicate information. For example, information about the physical state of the shoe or a motivational message can communicated to the user.
The advantages of the present invention include, without limitation, that it is able to degrade the material of the sole or insole in a controlled manner that tracks the areas of contact with either the ground or foot, respectively, and provides a means of quantifying the amount of material degraded due to the quantity of contact.
Referring now to the invention in more detail,
In further detail, still referring
The multiple layers 14 of the insole 11 continue the length of the foot 10. The multiple layers 14 can be composed of different materials such as rubber, plastics, and the like, and also of different colors and textures. These multiple layers 14 can also be composed of different densities or thicknesses of materials.
The multiple layers of the sole 15 also continue the length of the foot 10. The multiple layers can be composed of different materials such as rubber, plastics and the like, and also of different colors and textures. The multiple layers of materials can also be composed of different densities or thicknesses.
Both the multiple layers 14 of the insole 11 and multiple layers of the sole 15 can be developed or made using different manufacturing processes such as injection molding, heating and gluing, and the like. Those of skill in the art will be familiar with such processes and their suitability for use in the manufacture of insoles and soles for shoes.
The invention takes advantage of these areas of wear to utilize the exposed underlying layer(s) as a way to convey information. For example, the information may be motivational to encourage further physical activity by a child or adult, or the information may provide data about the physical state of the shoe and its remaining usable life. The exposed underlying layer(s) may comprise one or more different colors, graphic symbols, or words that can be used to provide information.
Another configuration of the invention is shown in
In
Friction between the sole 15 and the ground 9 causes the outermost layer of material 21 to degrade or wear away from the sole 15. After degradation of this outermost layer 21 of the sole 15, the next layer of material 22 of the sole 15 will be exposed and come in contact with the ground 9. Similarly, this next layer of material 22 can be degraded by friction with the ground 9 to expose one or more further underlying layers of the sole 15. Subsequent layers of the sole 15 can continue to degrade via friction with the ground 9 until the uppermost layer 22 of the sole 15 is exposed. Over time, degradation of a layer may be partial or even complete.
In
Both the multiple layers 14 of the insole 11 and multiple layers of the sole 15 can be developed or made using different manufacturing processes such as injection molding, heating and gluing, and the like. Those of skill in the art will be familiar with such processes.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs at the time of filing. The meaning and scope of terms should be clear; however, in the event of any latent ambiguity, definitions provided herein take precedent over any dictionary or extrinsic definition. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. Herein, the use of “or” means “and/or” unless stated otherwise. Furthermore, the use of the term “including”, as well as other forms such as “includes” and “included” is not limiting. Any patents and publications referred to herein are incorporated by reference.
All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention.
This application relates to and claims priority to U.S. Provisional Patent Application No. 61/801,389, which was filed Mar. 15, 2013 and is incorporated herein by reference in its entirety. All applications are commonly owned.
Number | Name | Date | Kind |
---|---|---|---|
6058627 | Violette | May 2000 | A |
7353770 | Sanguinetti | Apr 2008 | B2 |
8024872 | Pettis | Sep 2011 | B2 |
20140215861 | Burks | Aug 2014 | A1 |
Number | Date | Country |
---|---|---|
1055377 | Nov 2000 | EP |
2411336 | Aug 2005 | GB |
Number | Date | Country | |
---|---|---|---|
20140259745 A1 | Sep 2014 | US |
Number | Date | Country | |
---|---|---|---|
61801389 | Mar 2013 | US |