Patent Application
20170360150
The present invention relates to static dissipating and conductive footwear, and methods for manufacturing such footwear.
Static dissipating and conductive footwear are available from a variety of footwear suppliers. Conventional static dissipating and conductive footwear are designed to provide a conductive path from wearer's foot through an article of footwear to ground. In use, this flow path allows static electricity and other electrical charges to dissipate from an individual to the ground. In the context of static dissipating footwear, an appropriately-sized resistor is generally provided along the flow path. For example, applicable ASTM standards provide for static dissipative footwear to have electrical resistance between 1M ohm and 100M ohm. Conductive footwear is designed to have significantly lower electrical resistance. Applicable ASTM standards provide for conductive footwear to have electrical resistance between 0 and 500K ohms.
In a typical article of static dissipating or conductive footwear, the footbed or insole is provided with conductive elements that are arranged to contact the bottom of the wearer's foot. The footbed or insole is, in turn, electrically coupled to the midsole and outsole. For example, the midsole may include a conductive strap that extends along the top, wraps around the side and extends along the bottom of the midsole. The outsole may be manufactured from a conductive material. For example, the outsole material may be inherently conductive or it may be doped with an additive that renders the finished outsole conductive.
The conventional approach suffers various disadvantages. First, conventional aftermarket orthotics, footbeds and insoles cannot be used with static dissipating and conductive footwear because they are not conductive and would not provide a conductive path from the wearer's foot to the midsole. This can significantly affect comfort for individuals that prefer aftermarket footbeds/insoles, and may present even greater problems for those individuals that require custom orthotics. In fact, this can effectively prevent an individual with an acute need for orthotics from using conventional static dissipating footwear and conductive footwear. Second, it can be relatively costly to incorporate conductive elements into a footbed or insole in a way that reliably provides the desired electrical flow path. Third, the presence of conductive elements in the footbed or insole can impact other performance characteristics, such as cushioning and support. For example, design choices for the footbed or insole may be limited by the need to provide a conductive electrical flow path.
The present invention provides static dissipating and conductive footwear in which an electrical flow path is provided in the upper. The upper includes at least one conductive element extending along at least a portion of the inside of the upper in a position where it will directly contact the wearer's foot. In some applications, the upper may include a plurality of conductive elements located in different regions to collective provide improved electrical contact with the wearer's foot. For example, conductive elements may be positioned along the inside the tongue and/or along the inside of the quarter on both sides of the tongue.
The conductive elements may be positioned in essentially any region or number of regions where electrical contact can be established with the wearer's foot. In one embodiment, the conductive elements may be positioned in line with the lacing structure so that tightening of the laces urges the conductive elements into greater contact with the wearer's foot.
In one embodiment, the conductive element is a flexible conductive material that is sewn or otherwise affixed to the inside of the upper. The flexible conductive material may be a ribbon or other strip of fabric that includes one or more conductive threads. The ribbon or fabric strip may be woven in and out of the lining material, if desired.
In one embodiment, the conductive element(s) may be positioned in alignment with the closure system for the article of footwear so that the forces applied by the closure system may assist in providing electrical contact between the wearer's foot and the conductive elements. For example, with footwear that includes a tongue opening and a lacing system, the conductive element(s) may be positioned on the inside of the upper on lateral and/or medial sides of the tongue opening so that tightening of the laces draws the conductive element(s) into firm engagement with the top of the wearer's foot.
In one embodiment, the conductive element or elements can be incorporating into functional upper components. It is not uncommon for footwear uppers to include webbing or straps that are strategically positioned to reinforce or provide enhance strength in select regions of the upper. For example, a variety of footwear uppers include sections of webbing, such as nylon straps, that extend upwardly from the sole and either directly receive the laces or support a lacing eyelet or similar lacing element. In one embodiment, one or more conductive elements are incorporated into one or more lacing straps. When the laces are tightened, the associated forces may draw the straps, and consequently the conductive elements, into firm contact with the wearer's foot.
In one embodiment, the upper wraps beneath the footbed or insole and is in electrical contact with the midsole. As a result, a conductive path is formed from the wearer's foot to the midsole through the conductive element(s) in the upper. To complete the conductive path to ground, the midsole is electrically coupled to the outsole and the outsole is electrically coupled to ground. For example, a conductive strap may be provided that extends along the top, wraps around the side and extends along the bottom of the midsole. The outsole may be manufactured from a conductive material. For example, the outsole material may be inherently conductive or it may be doped with an additive that renders the finished outsole conductive. The conductive flow path may include a resistor when appropriate to provide the desired electrical resistance.
In one embodiment, the upper may include a lining material that is conductive throughout or has one or conductive regions. For example, the lining material may be knitted, woven or otherwise formed from threads, yarns other elements that are conductive. As another example, the lining material may be manufactured from underlying material that is nonconductive, but include conductive threads that are added to the underlying material to provide the desired conductivity.
The present invention provides a simple and effective construction that is easily incorporated into a wide range of footwear article. The present invention provides static dissipation and conductive footwear that can be used with conventional aftermarket footbeds and shoe inserts, as well as custom orthotics. The conductive elements can be easily positioned at one or more locations within the upper. The location or locations can be selected to facilitate reliable electrical contact with the wearer's foot. In some applications, the conductive elements can be disposed in or near lacing components so that tightening or other engagement of the lacing components can assist in providing electrical contact between the wearer's foot and the conductive elements.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z ; and Y, Z.
An article of footwear 10 incorporating a conductive system 12 in accordance with an embodiment of the present invention is shown in
Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. Further, the terms “medial,” “lateral” and “longitudinal” are used in the manner commonly used in connection with footwear. For example, when used in referring to a side of the shoe, the term “medial” refers to the inward side (that is, the side facing the other shoe) and “lateral” refers to the outward side. When used in referring to a direction, the term “longitudinal direction” refers to a direction generally extending along the length of the shoe between toe and heel, and the term “lateral direction” refers to a direction generally extending across the width of the shoe between the medial and lateral sides of the shoe. The use of directional terms should not be interpreted to limit the invention to any specific orientation.
Further, as used herein, the term “arch region” (or arch or midfoot) refers generally to the portion of the footwear or sole assembly corresponding to the arch or midfoot of the wearer's foot; the term “forefoot region” (or forefoot) refers generally to the portion of the footwear forward of the arch region corresponding to the forefoot (for example, including the ball and the toes) of a wearer's foot; and the term “heel region” (or heel) refers generally to that portion of the footwear rearward of the arch region corresponding to the heel of the wearer's foot. The forefoot 90, arch 92 and heel 94 regions are generally identified in
For purposes of disclosure, the present invention is described in the content of a static dissipating or conductive shoe. The present invention may, however, be incorporating into essentially any style or type of footwear that incorporates an upper and a sole. For example, the present invention may be incorporated into essentially any safety shoes, safety boots, work shoes, work boots, athletic shoes, running shoes, sneakers, tennis shoes, hiking shoes, hiking boots, biker boots, boat shoes, deck shoes, dress shoes, military footwear, uniform footwear and sandals.
The present invention is described in the context of the article of footwear shown in
As noted above, the upper 16 includes one or more conductive elements 14 that are configured to engage the wearer's foot when it is seated in the interior of the upper 16. The present invention may be implemented with essentially any conductive element capable of providing an electrical flow path from the wearer's foot to the sole 18. In the illustrated embodiment, the conductive elements include a plurality of ribbons 14 (or other fabric strips) that are integrated into the upper 16. The ribbons 14 may be manufactured from inherently conductive materials or conductive materials may be added to the ribbons 14 to provide adequate conductivity. For example, conductive threads may be incorporated into the ribbons 14 during manufacture or may be added to the ribbons 14 after manufacture. In the illustrated embodiment, each ribbon 14 is manufactured from nylon and is provided with a plurality of conductive threads that extend longitudinally along the full length of the ribbons. More specifically, each of the illustrated ribbons 14 includes six conductive threads 15 (but the number may vary) that are spaced apart and extend parallel to one another along the full length of the ribbon. The ribbons 14 (or other conductive elements) may be positioned in essentially any region or number of regions where electrical contact can be established with the wearer's foot. As perhaps best shown in
In the illustrated embodiment, the conductive element includes additional elements secured to the lining material 46 (or liner). Alternatively, the conductive element may be in the form of a conductive lining material 46. For example, the lining material 46 may be provided with conductive threads or be formed from conductive strands, and a portion of the lining material containing the conductive threads or strands may be brought into contact with the midsole conductive element to provide an electrical flow path from the wearer's foot to the sole 18. In one embodiment, conductive threads (not shown) may be sewn or embroidered into the lining material 46 after the lining material 46 has been formed. In another embodiment, the lining material 46 may be formed with conductive strands (e.g. warps/wefts if a woven material). In applications where the lining material forms the conductive element, the lining material may extend beyond the remainder of the upper so that the lining material may be brought into direct contact with the midsole conductive element.
In the illustrated embodiment, the bottom of the upper 16 is closed by a lasting board 54. The lasting board 54 of the illustrated embodiment is generally conventional and therefore will not be described in detail. Suffice it to say that the lasting board 54 may be manufactured from essentially suitable material, and may be shaped to provide the closed bottom of the upper 16 with the desired shape. In the illustrated embodiment, the bottom end of the upper 16 terminates in a lasting allowance 50 that is wrapped inwardly beneath and is joined to undersurface of the lasting board 54. In the illustrated embodiment, the lasting allowance 50 is secured to the lasting board 54 by adhesive. Although the illustrated embodiment includes a board lasted construction, the present invention may be incorporated into other footwear constructions, such as strobel constructions, welted constructions, slip lasted constructions and direct-attach constructions, just to name a few examples. In each of these alternative constructions, the upper conductive elements 14 are configured to engage the sole 18 (e.g. the midsole 20 or the outsole 22) to provide a conductive flow path from the wearer's foot to the sole 18. As shown in
As noted above, the sole assembly 18 generally includes a midsole 20 and an outsole 22. One of the primary functions of the midsole 20 is to provide resilient cushioning for the wearer's foot. Although the midsole 20 may vary from application to application, the midsole 20 of the illustrated embodiment is manufactured from a relatively resilient material selected to provide the sole assembly 10 with a desired level of cushioning. For example, the midsole 20 may be formed from ethyl vinyl acetate (“EVA”) foam, expanded thermoplastic polyurethane (“E-TPU”) foam, thermoplastic elastomer (“TPE”) foam or polyurethane (“PU”) foam. The specific characteristics of the selected foam may vary from application to application. However, in the illustrated embodiment, the midsole 20 hardness is in the range of 55-60 Shore C or more broadly in the range of 40-60 Shore C.
In the illustrated embodiment, the midsole 20 is first manufactured and then attached to the upper 16. In this embodiment, the top surface 34 of the midsole 20 is configured to be secured to an upper 16, for example, to the underside of the lasting board. The midsole 20 may be secured to the upper (not shown) using any suitable attachment, for example, by adhesives or stitching. These are simply examples and the midsole 20 may be secured to the upper using other techniques and apparatus. For example, the midsole 20 may be direct-attached to the upper. Although the illustrated midsole 20 is generally continuous in the illustrated embodiment, it may be implemented in discrete parts.
The midsole 20 of the illustrated embodiment includes a conductive element 26 that is configured to be electrically coupled to the upper conductive element(s) 14 and to the outsole 22. In the illustrated embodiment, the midsole conductive element 26 is a single conductive strand disposed along the top surface 34 of the midsole 20. The midsole conductive element 26 may be conductive webbing, thread or tape. The midsole conductive element 26 is secured to the midsole 20, for example, by adhesive. In this embodiment, the midsole conductive element 26 is electrically coupled to the upper conductive elements 14 by direct contact. More specifically, the ribbons 14 are wrapped beneath the lasting board 54 and positioned to be in direct contact with the midsole conductive element 26 when the midsole 20 is secured to the bottom of the upper 16. To facilitate the electrical coupling, the adhesive used to the secure the midsole 20 to the upper 16 may be electrically conductive or adhesive may be absent in the regions where the ribbons 14 and midsole conductive element 26 overlap. Although the ribbons 14 and midsole conductive element 26 are electrically coupled by direct contact, they may be electrically coupled by an intermediate conductive element, such as a conductive layer on the bottom of the lasting board 54.
In the illustrated embodiment, the midsole conductive element 26 is electrically coupled to the outsole 22. This electrical coupling can be provided in essentially any way. However, in the illustrated embodiment, the midsole conductive element 26 extends through the midsole 20 and is coupled to an outsole conductive element 28 extending along the top surface of the outsole 22. Referring now to
As noted above, the sole 18 includes an outsole 22 that is configured to provide a durable, high traction ground-engaging structure. In the illustrated embodiment, the outsole 22 is disposed below the midsole 20. In the illustrated embodiment, the outsole 22 is manufactured from a single, one-piece layer that extends over the entire bottom surface of the midsole 20. The outsole 22 need not, however, cover the entire bottom surface of the midsole 20, and it may be manufactured from a plurality of discrete segments that are separately secured to the undersurface of the midsole 20. For example, in alternative embodiments, the outsole may include a forefoot section that is secured to the undersurface of the midsole 20 in the forefoot region of the shoe 10 and a heel section that is secured to the undersurface of the midsole 20 in the heel region. In this alternative embodiment, there may be no outsole in the arch region. Instead, the arch region of the midsole 20 may be exposed. In the illustrated embodiment, the bottom surface of the outsole may also include a plurality of ground engaging lugs 70 or otherwise be textured or contoured to provide the desired performance characteristics. The number, size, shape, arrangement and configuration of lugs 70 may vary from application to application.
In the illustrated embodiment, the outsole 22 is manufactured as a single, unitary component formed from an electrically conductive material. The outsole 22 may alternatively be manufactured from a plurality of different materials with one or more portions being non-conductive and one or more portions being electrically conductive. The outsole 22 may be manufactured from a material that is inherently conductive or that includes an additive that renders the outsole 22 sufficiently conductive. In the illustrated embodiment, the outsole 22 is constructed from rubber that includes an additive to ensure that it is sufficiently conductive. Alternatively, the outsole 16 can be constructed from a thermoplastic polyurethane elastomer (TPU), synthetic rubber, nylon or other polymer blends that includes nylon and/or TPU. If the desired outsole material is not sufficiently conductive, the material may be provided with an additive to provide the desired level of electrical conductivity. These materials are merely exemplary, and the outsole 22 can be constructed from essentially any relatively wear resistant polymer, elastomer and/or natural or synthetic rubber or other materials capable of providing the desired functional characteristics. The outsole also can be constructed to include thermoplastic elastomers and/or thermoset elastomers. Other materials such as fiber-reinforced polymers can be used. These can include epoxy, polyethylene, polyester, thermosetting plastic reinforced with carbon, glass and/or aramid fibers.
As noted above, the outsole 22 of the illustrated embodiment includes a conductive element 28 that is configured to be electrically coupled to the outsole 22 and to the midsole conductive element 26. In the illustrated embodiment, the outsole conductive element 28 is a single conductive strand disposed along the top surface 36 of the outsole 22, but its position may vary. The outsole conductive element 28 may be conductive webbing, thread or tape. The outsole conductive element 28 is secured to the top surface 36 of the outsole 22, for example, by an electrically conductive adhesive. In this embodiment, one end of the outsole conductive element 28 is electrically coupled to the midsole conductive element 26. For example, one end of the outsole conductive element 28 may be joined to the midsole conductive element 26 by soldering, by twisting or by an electrical connector. In the illustrated embodiment, a resistor 24 is connected in series between the midsole conductive element 26 and the outsole conductive element 28. The resistor 24 is selected to have the desired an electrical resistance. In the context of a static dissipating article of footwear, the resistor 24 may be selected to provide the electrical flow path 14 with an electrical resistance of between 1M ohm and 100M ohm. For conductive footwear, the resistor may be eliminated or replaced with a resistor selected to provide the electrical flow path 14 with an electrical resistance of between 0 ohm and 500K ohm.
The article of footwear 10 may also include additional cushioning and/or support components. For example, one or more additional cushioning or support elements may be incorporated into the article of footwear 10 above the midsole 20. Although not shown, an inner sole, insole, footbed, orthotic or other type of cushioning component may be fitted into the interior of the upper 16 to underlie the wearer's foot and provide additional cushioning and/or support.
In alternative embodiments, the conductive elements in the upper may bypass the midsole and be in electrical contact with the outsole. For example,
Another alternative embodiment is shown in
In another alternative embodiment, the conductive element(s) can be incorporating into functional upper components. It is not uncommon for footwear uppers to include webbing or straps that are strategically positioned to reinforce or provide enhance strength in select regions of the upper. For example, a variety of footwear uppers include sections of webbing, such as nylon straps, that extend upwardly from the sole and either directly receive the laces or support a lacing eyelet or similar lacing element. These sections of webbing can be provided with conductivity and can be electrically coupled to the sole in any of the various ways discussed above. In an alternative embodiment shown in
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.
