Footwear

Abstract

Footwear having one or more reinforcement features is disclosed. Footwear having two independent components constructed from a woven material with the strands oriented at specified angles to the plane of the sole of the footwear is disclosed. The footwear may also incorporate a substantially rigid structural collar in the area of the ankle or lower leg. Heel and/or forefoot straps that wrap downwardly and laterally around the heel and/or forefoot may be provided to limit flexing of the ankle and the footwear in a forward or backward direction, respectively. An internal reinforcement structure comprising a plurality of support strips arranged transversely to one another in a criss-cross arrangement is also disclosed.

Description

REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/207,550, filed Dec. 8, 1998 and of PCT International Application No. PCT/US99/29246 filed Dec. 8, 1999.

FIELD OF THE INVENTION

[0002] The present invention relates to footwear having improved support, flexibility, comfort and structural properties and, optionally, footwear provided with an internal reinforcement system The present invention also relates to components that, when incorporated into footwear, provide improved support, flexibility, comfort and structural properties. The improved footwear, footwear components, and techniques of the present invention are particularly suitable for active outdoor footwear applications, including boots for skiing, snow and water boarding, skating, including ice skating and in-line skating, hiking, and both indoor and outdoor athletic activities.

BACKGROUND OF THE INVENTION

[0003] Footwear designed for active sports, such as skiing, skating, hiking, and the like, is highly specialized. Yet, there are several common requirements. Such footwear must be somewhat stiff to provide support and protection for the foot, yet it must be somewhat flexible to permit movement and, to the greatest degree possible, comfort. Generally, footwear designed for more physically demanding sports applications, such as downhill skiing, in-line skating and mountaineering, incorporates a rigid outer structure with movement provided only at certain pivot points. Footwear for high performance applications requires the footwear, and the sporting equipment to which it is fastened (skis, snowboards, skates, and the like), to closely track movements of the foot, yet footwear having a high degree of rigidity has generally been used for high performance applications as well. Footwear having a rigid, unbreathable outer shell is generally quite uncomfortable, notwithstanding the use of cushioned and removable inserts designed to provide comfort for the foot.

[0004] Footwear having a somewhat “soft,” flexible outer shell is available for some sporting activities, such as snowboarding, hiking and many athletic sporting activities. This footwear, while it is generally more comfortable, does not provide the structural rigidity necessary for safety and for many high performance and endurance activities.

[0005] The footwear, footwear components and methods of the present invention may employ a flexible outer shell in combination with an internal reinforcement system to provide the stiffness and flexibility required for high performance and endurance activities and may be adapted for a variety of footwear applications.

SUMMARY OF THE INVENTION

[0006] Footwear of the present invention exhibits improved comfort, flexibility, support and structural properties. According to one aspect of the present invention, one footwear component is constructed from a woven material that shifts to conform to the shape of the foot, yet that limits movement of the foot. The woven component may comprise two independent woven components having strands oriented in a particular orientation. The woven component(s) comprise at least two sets of strands oriented at generally right angles to one another and may compose an outer, inner or intermediate layer of the footwear. In this embodiment, one or more woven components is provided at the heel portion of footwear and one or more woven pieces is optionally provided at the forefoot portion of the footwear. In a preferred embodiment, the woven heel and forefoot components are each constructed from an integral fabric piece and preferably form an inner liner or an intermediate layer of the footwear.

[0007] The woven component is provided at least in the heel portion of the footwear is constructed and assembled in the footwear so that a first set of strands is oriented generally at from 60° to 120° to the plane of the sole of the footwear, and a second set of strands is oriented at about 90° to the first set of strands. The woven heel component may be structured as a generally cylindrical component that is affixed at a lower edge in proximity to the footwear sole, and may be affixed, as well, in the area of the footwear opening in proximity to the lace-up portion of the footwear. The heel woven component may be provided as a liner, or as an intermediate layer in multi-layered footwear, or as an outer layer in certain athletic footwear. The woven heel component is structured and mounted so that the cylindrical heel portion is free to shift, as a cylindrical component, to conform to the shape and movement of the heel portion and/or ankle portion of the foot during movement within the footwear. The shifting of the woven heel component during movement is, however, limited by shifting capacity of the woven fabric. The woven heel component preferably is generally cylindrical in configuration, with the component forming at least about 70% of a closed cylinder. There may be an opening, or gap, in the woven heel component in the area of the footwear closure. In alternative embodiments, the woven heel component may be provided as an inner layer and may be separately closable in proximity to the footwear closure to form a closed cylinder when the footwear is mounted and closed on the foot.

[0008] The composition and structure of the woven material is chosen to provide durability and to permit limited shifting during movement of the foot, yet to prevent movement of the foot and ankle region beyond certain parameters. In particular, the foot is prevented from lifting substantially above the plane of the sole, and the ankle is preventing from twisting substantially by the action of the woven component, while the woven component flexes to conform to the shape of the foot and provides limited shifting of the heel portion of the foot and ankle. Woven fabrics having suitable properties are well known and may be chosen by one of ordinary skill in the art. Woven materials such as nylon, coated fabrics, fabrics bonded to relatively thin cushioning layers, etc. are suitable.

[0009] Additionally, it is important that movement and shifting of the woven heel component is not constrained by other footwear features or attachments or fastenings. Thus it is preferred, for example, that the woven heel component is fastened to another footwear component along at least two of its peripheral edges, but not in any other region. Such attachments would limit the desired shifting of the woven heel component. Additionally, it is important in connection with multi-layered footwear that the woven heel component is provided as an inner layer that lies adjacent the foot, or as an intermediate layer if bonded to a flexible material, such as a padding layer, so that the woven heel component is capable of limited shifting during movement of the foot. The woven heel component is independent of any internal reinforcing structures, as described below.

[0010] The woven component optionally provided at the forefoot portion of the footwear is constructed and assembled in the footwear such that one set of strands wraps laterally around and follows the contour of the forefoot, while another set of strands is oriented at about 90° to the first set of strands. In this embodiment, a first set of strands in the woven component forming the forefoot portion is oriented generally at 45° to the plane of the sole, and another set of strands is oriented at about 90° to the first set of strands.

[0011] The woven heel component serves as a heel hold element that tends to hold the heel in the heel pocket and in proximity to the insole during activities. The orientation of the strands of the heel component limits movement of the heel in certain directions, yet the woven heel component is soft, flexible and comfortable. The heel component is preferably mounted to the sole or insole, or another structural footwear component, such that it is generally stationary during use and is not adjustable. The woven heel component is generally provided as an inner or intermediate layer in footwear designed for outdoor activities, such as ski and snowboard boots that have a rigid or flexible outer shell. Alternatively, the woven heel component may be provided as the outer layer, or the only layer in certain types of athletic footwear. It is important that other components of the footwear not interfere with the heel hold forces exerted by the heel component during activity. That is, the other footwear components, the assembly of the other components and their relationship to the heel component, the lacing system and the like, are arranged to complement rather than interfere with the heel hold forces.

[0012] Heel and forefoot woven components may be joined to provide a footwear liner. This arrangement provides footwear that “hugs” and snugly retains the heel and forefoot in position in the footwear, even during athletic activities. Footwear constructed of woven heel and forefoot components in this fashion provides a high degree of flexibility and comfort, yet provides a degree of firmness and stability that is highly desirable for athletic activities and high performance sports activities.

[0013] According to another aspect of the present invention, footwear of the present invention preferably comprises a collar having one or more support straps mounted to the collar. The collar preferably encircles the ankle or lower leg of a person wearing the footwear and is adjustable and/or releasable to permit entry and withdrawal of the foot from the footwear. The collar may be positioned at the exterior or interior surface of the footwear, but is preferably provided intermediate the exterior and interior surfaces, and may be provided, for example, as an intermediate component of a padded collar. The collar is preferably adjustable and may be tightened to snugly position the footwear after it has been placed on the foot.

[0014] One or more straps may be mounted to the collar to provide support and limit flexing of the ankle in a backward or forward direction, or in both backward and forward directions. Specialized straps may be provided for different athletic activities. The straps may be provided on the exterior of the footwear, or they may be provided proximate an interior lining or intermediate the exterior and interior surfaces of the footwear. In one embodiment, external or internal straps are provided that criss-cross the heel portion of the footwear to provide forward support, and to limit flexing of the ankle in a forward direction. Thus, one strap is mounted to the collar at a medial side portion of the footwear and wraps downwardly and laterally around the heel to a lower position on the lateral side of the footwear. Similarly, another strap is mounted to the collar at the lateral side portion of the footwear and wraps downwardly and laterally around the heel to a lower position at the medial side of the footwear. These straps criss-cross at a generally central heel portion of the footwear and provide support that resists or limit forward bending of the ankle.

[0015] Alternatively or additionally, another set of support straps may be provided that criss-crosses the forefoot portion of the footwear. Thus, one strap may be mounted to the collar at a medial side portion of the footwear to extend downwardly and laterally across the top of the forefoot to a lower position on the lateral side of the footwear. Similarly, a second forefoot strap may be mounted to the collar at a lateral side of the footwear to extend downwardly and laterally across the top of the forefoot to a lower position at the medial side of the footwear. These forefoot straps criss-cross at a generally central forefoot portion of the footwear and provide support that resists or limits backward bending of the ankle. The heel and forefoot straps may be used independently or in combination, depending on the support desired for particular footwear applications.

[0016] The straps themselves may be flexible, or they may be substantially rigid, and they are preferably adjustable to provide a desired degree of support. According to an especially preferred embodiment, one or both sets of straps are provided on the exterior of the footwear and are adjustably mounted to the collar to provide an adjustable level of support for various activities, or for various levels of performance or terrain. According to another embodiment, one or both sets of straps is removably or releasably mounted to the collar at respective pivot points to provide a high degree of support, flexibility and comfort.

[0017] Yet another aspect of the present invention relates to an internal reinforcement structure mounted to and extending below the substantially rigid collar. The internal reinforcement structure is preferably mounted intermediate the collar and the sole of the footwear in the area of the heel. This reinforcement structure provides a high degree of structural firmness and support, yet it does not compromise the flexibility and comfort of the footwear. The internal reinforcement structure serves to limit compression along a generally vertical axis, yet permits limited lateral flexing of the ankle portion of the footwear article.

[0018] According to preferred embodiments, the internal reinforcement structure comprises a plurality of compression strips that criss-cross the heel portion of the footwear and are mounted to the collar and a lower structural portion of the footwear. Additionally, vertically and/or horizontally oriented reinforcing structures may be provided. The reinforcement strips are preferably constructed from a material that is substantially non-stretchable and non-compressible in the direction of its longitudinal axis, but that is flexible to permit limited lateral and front to back flexing of the ankle and lower leg. Numerous exemplary embodiments are described below and may be adapted for use in various footwear applications.

[0019] Although the internal reinforcement structure is described generally as a criss-crossing multiple strip or webbed structure, it will be understood that other structures, such as perforated structures, layered structures, and the like, may also provide the desired internal reinforcement and are contemplated by the present invention. Structures having support elements that criss-cross around the heel are contemplated.

[0020] The various aspects of footwear construction and structural components may be used alone or in combination to provide the improved footwear of the present invention. Numerous exemplary embodiments are described below, but the invention is not intended to be limited to these specific embodiments.

DESCRIPTION OF THE FIGURES

[0021] Preferred embodiments of the present invention will be described with reference to the figures, in which:

[0022] FIG. 1 illustrates footwear of the present invention comprising a woven heel component and a woven forefoot component;

[0023] FIG. 2 illustrates footwear of the present invention employing both heel and forefoot external support straps mounted on a collar;

[0024] FIG. 3 illustrates an internal support structure comprising a footbed, a criss-crossing internal reinforcement structure, and a collar element;

[0025] FIG. 4 illustrates another embodiment of an internal reinforcement structure of the present invention;

[0026] FIG. 5 illustrates a rear view of footwear incorporating an internal support structure, shown in dashed lines;

[0027] FIG. 6 illustrates another embodiment of footwear incorporating an internal support structure including generally vertical front stays, the support structure shown in dashed lines;

[0028] FIG. 7 illustrates a side view of footwear incorporating an internal support structure including both front and rear support, the support structure shown in dashed lines;

[0029] FIG. 8 shows a side view of another footwear embodiment incorporating an internal support structure of the present invention, the support structure shown in dashed lines;

[0030] FIG. 9 illustrates a side view of another footwear embodiment incorporating an internal reinforcement structure of the present invention, the reinforcement structure shown in dashed lines;

[0031] FIG. 10 illustrates a side view of yet another footwear embodiment comprising an internal reinforcement structure of the present invention, the reinforcement structure shown in dashed lines;

[0032] FIG. 11 illustrates a side view of another footwear embodiment comprising an internal reinforcement structure of the present invention, the reinforcement structure shown in dashed lines;

[0033] FIG. 12 illustrates a side perspective view of another footwear embodiment of the present invention with an internal reinforcement structure shown in dashed lines; and

[0034] FIG. 13 illustrates a side perspective view of another yet another footwear embodiment of the present invention with an internal reinforcement structure shown in dashed lines.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0035] Footwear and components of the present invention are described below with reference to certain preferred embodiments, such as boots and athletic footwear. The components and footwear of the present invention are not limited for use in such applications or in connection with component assemblies and footwear having similar configurations or properties. Broadly, the methods and components of the present invention may be used to provide footwear of many types providing improved comfort, performance and structural properties.

[0036] FIG. 1 illustrates a boot 10 embodying several features of improved footwear of the present invention. The boot comprises an exterior heel component 12 mounted to an exterior forefoot portion 14, with both the heel and forefoot components mounted to an insole (not shown) and an outsole 16. Toe portions 18 and 20 are preferably reinforced using rubber or various synthetic compounds, as is known in the art. Boot 10 may employ standard construction techniques with a standard closure structure including lacing 22 threaded through eyelets 24 and criss-crossing a tongue 26 mounted between the split that permits entry and withdrawal of the foot from the footwear. Tongue 26 is preferably composed of a flexible stretchy material, and is attached to the outsole using gussets that fold on top of the tongue when the footwear is laced. Tongue 26 may also comprise another layer of relatively stiff material that serves to spread the pressure of the laces when the footwear is laced tightly.

[0037] A heel component 12 of the present invention preferably comprises a woven material having at least two sets of strands oriented at generally right angles to one another. Thus, as shown, heel component 12 comprises a woven material comprising a plurality of strands A oriented generally vertically and a plurality of strands B oriented generally horizontally with reference to the plane of the inner surface 17 of outsole 16. The strands intersect one another at generally right angles. According to certain preferred embodiments, strands B are oriented generally parallel to, or at an angle of up to 30° from the plane of the inner surface 17 of outsole 16. Similarly, strands of the woven fabric are preferably at generally right angles, although variation on the order of from 80° to 100° may be tolerated. Forefoot component 14 of the present invention preferably comprises a woven material having at least two sets of strands oriented at generally right angles to one another and oriented generally transverse to the orientation of the strands comprising woven heel component 12. Thus, as shown, forefoot component 14 comprises a woven material comprising a plurality of strands C intersecting a plurality of strands D at generally right angles. Strands C and D are oriented generally transversely to strands A and B of woven heel component 12.

[0038] Woven heel portion 12 may be an integral component constructed from a plurality of similarly oriented woven components joined to one another, but it is preferably provided as a unitary woven piece, as shown. Heel portion 12 may be provided as an exterior surface in footwear having woven exterior surfaces. Alternatively, heel portion 12 may be provided as an intermediate or inner liner layer in footwear having a different exterior surface. Heel portion 12 is preferably provided as a unitary, woven, shaped component having contours that substantially match the contours of a heel. Heel component 12 may be positioned as a footwear liner, for example, such that the apex of the woven heel curve of component 12 is below the anatomical heel apex of a foot when positioned in the footwear. This positioning allows the fabric to pre-load and provides a tighter, but comfortable heel hold. According to a preferred embodiment, the apex of the curved woven heel component 12 is positioned within ½ inches from the upper surface of the foot heel. In an alternative embodiment, heel component 12 may be part of a unitary exterior, interior or intermediate layer or liner that does not incorporate a forefoot portion having strands in a different orientation. A unitary outer is illustrated, for example, in FIG. 2.

[0039] Heel component 12 is preferably mounted to a generally rigid and/or stationary element of the footwear. The orientation of the woven strands of heel component 12 hugs and snugly retains the heel in position, even during movement and athletic activities. Woven heel component 12 preferably substantially spans the height of the footwear and, as shown, extends from the sole to a padded collar 32. Similarly, woven forefoot portion 14 may be an integral component constructed from a plurality of similarly oriented woven components joined to one another, but it is preferably provided as a unitary woven piece, as illustrated in FIG. 1, or as two mirror image side (medial and lateral) forefoot sections having a similar configuration and orientation. The woven forefoot components may be attached to one another and to the other structural components of the footwear using conventional footwear construction techniques.

[0040] The woven material comprising woven heel component 12 and optional woven forefoot component 14 preferably comprises at least two sets of strands oriented at generally right angles to one another. Additional strands may be provided in other orientations. The woven material preferably has a high strength and is biased, that is, the fabric does not move or “stretch” in the direction of the grain (the strands, as described), but it may move, or shift, in a direction at an angle to the grain. The strands themselves are preferably non-stretchable, but the shifting of the strands with respect to one another provides a limited degree of “stretch” at an angle to the grain. Natural and/or synthetic materials may be used, depending on the footwear application. Woven materials that provide a degree of breathability are preferred. Heavy gauge nylon cordura materials may be used, for example, for outdoor athletic footwear applications. Lighter gauge woven materials may be used for athletic footwear for court sports, such as basketball, tennis, squash, handball, racket ball and the like, having woven heel and forefoot components assembled as described above. Specialized outsoles and other footwear features may be provided, depending on the particular application.

[0041] The orientation of strands in woven heel component 12 snugly retains the wearer's heel in position in the footwear during activities. Selection and management of other footwear components is important and must not interfere with the forces exerted on the woven heel component. Footwear components, such as the fastening (lacing) components, may be designed and arranged to complement the holding features of the woven heel component. In embodiments in which the woven heel component 12 is provided as a liner and an outer footwear shell is employed, eyelets for laces are preferably fastened independently to the outer shell and the woven heel component liner so that when the laces are tightened, both the woven heel component and the outer shell are tightened to snugly retain the heel.

[0042] FIG. 2 illustrates another feature of footwear of the present invention that may be employed in combination with or independently of the woven heel and/or woven forefoot components described above. Footwear components illustrated in FIG. 2 and the remaining figures incorporate the numerals used in connection with the corresponding components described above. The improved structural components of FIG. 2 include a structural collar 34 provided generally above the ankle and, preferably, in proximity to or forming the upper portion of the footwear. Collar 34 encircles lower leg portion of the wearer above the ankle and provides an attachment point for optional structural reinforcement components of the present invention. Structural collar 34 may be exposed to the exterior of the footwear at some point around its perimeter and provided with means for release and/or adjustment mechanisms permitting entry of the foot into and withdrawal of the foot from the footwear. Conventional release and/or adjustment mechanisms, such as buckles, cinch mechanisms, and the like, may be used and are not illustrated. Alternatively, structural collar 34 may be designed to encircle only a portion of the user's foot, so that fastening and adjustment means are not necessary.

[0043] Collar 34 may be provided on an exterior or interior surface of the footwear, but it is preferably provided intermediate the exterior and interior surfaces and, according to a preferred embodiment, may be provided in proximity to a padded collar for comfort and ease of construction. In one embodiment, collar 34 preferably comprises a material that is substantially rigid, and that is not stretchable along its circumferential axis, but may be somewhat flexible in other directions. The material comprising collar 34 has high flexural strength so that it conforms to the ankle or leg of the wearer during activities, yet remains a semi-rigid and durable structure for mounting and supporting additional structural components. Materials such as reinforced fiberglass, semi-rigid plastics, synthetic resins, metallic sheet materials, carbon fiber materials, and composite materials are preferred. Injection molded plastics are suitable materials. According to one embodiment, Collar 34 comprises multiple layers of material bonded together, the layers having strands oriented to provide the desired rigidity flexural strength. Collar 34 may be provided as a strip having a generally uniform width and thickness, or portions of the collar that serve as attachment points may be reinforced by providing, for example, additional material. Collar 34 is preferably at least 0.5 inch high, and more preferably at least about 0.75 inch high.

[0044] Collar 34 may provide attachment points, for example, for heel straps 36A and 36B and/or forefoot straps 38A and 38B. Heel straps 36A and 36B may be affixed at attachment points 40 provided in corresponding locations on the medial and lateral portions of collar 34. In the embodiment shown in FIG. 2, one end of strap 36A is affixed to collar 34 at attachment point 40 on collar 34 on lateral portion of the footwear and the other end extends in a criss-cross fashion around the heel portion of the footwear, and is anchored on the medial portion of the footwear in proximity to the sole. The complementary heel strap 36B is affixed at an attachment point on collar 34 on the medial portion of the footwear and the other end extends in a criss-cross fashion around the heel portion of the footwear, and is anchored on the lateral portion of the footwear in proximity to the sole, as shown.

[0045] Similarly, one end of forefoot strap 38A is affixed to collar 34 at an attachment point on a medial portion of the footwear and extends in a cross-cross fashion across the upper forefoot portion of the footwear and across the closure system, and is anchored on the lateral portion of the footwear in proximity to the sole. The matching forefoot strap 38B is affixed at an attachment point on collar 34 on the lateral portion of the footwear, extends in a cross-cross fashion across the forefoot portion of the footwear, and is anchored on the medial portion of the footwear in proximity to the sole, as shown. Forefoot straps 38A and 38B are preferably attached to the footwear intermediate the arch and the toe portion.

[0046] Heel and forefoot straps are preferably provided on the exterior of the footwear but may be provided adjacent an interior surface or lining of footwear, or may be provided intermediate the exterior and interior surfaces of the footwear. Exterior placement is preferred for comfort and accessibility. Support straps 36A, 36B, 38A and 38B are preferably adjustable using, for example, adjustment mechanism 42.

[0047] Each strap is preferably independently adjustable to provide specialized adjustment by the wearer depending on the level of terrain, activity, ability, desired performance and the like. Straps 36A, 36B, 38A and 38B may be rigidly or pivotably attached to collar 34 at attachment points 40. Attachment mechanisms that provide both pivotable and releasable attachment of external straps 36 and 38 to collar 34 may be used and are known in the art. Pivotable and releasable attachment of the external straps may be provided, for example, by rigidly mounting one or more pins on collar 34, with each of the pins penetrating to and protruding a bit from the exterior of the footwear at an enlarged head. According to this embodiment, external straps 36 and 38 may be provided with one or more reinforced eyelets that may be mounted on the enlarged head to engage the external straps and removed from the enlarged head to disengage the external straps. Multiple pins may be provided to accommodate multiple attachment points for the external straps. In this fashion, one or more pivotable attachment points for the external straps may be provided. Alternatively, adjustment mechanism 42 may comprise an adjustable hook and loop fastener, a buckle mechanism, or another type of adjustment mechanism.

[0048] The other ends of straps 36A, 36B, 38A and 38B may be attached at a seam of the footwear, or may be fastened between the upper and the sole, or to the sole, or to a sole plate provided with tabs as described in detail below. Support straps 36A, 36B, 38A and 38B are preferably substantially non-stretchable in the direction of their longitudinal axes, but are flexible and conform to the contour of the footwear and to provide some flexing during activity. A limited degree of stretch in the direction of longitudinal axes may be preferred for many types of athletic footwear. Woven webbing material, flexible plastics, and the like are suitable.

[0049] Heel straps 36A and 36B are employed in footwear applications in which it is desirable to limit flexing of the ankle in a forward direction. Similarly, external forefoot straps 38A and 38B are employed in footwear applications in which it is desirable to limit flexing of the ankle in a backward direction. Heel and forefoot straps may be provided independently of one another, or footwear of the present invention may comprise both heel and forefoot straps, as illustrated in FIG. 2. According to a preferred embodiment, heel and forefoot straps are releasably and pivotably attachable at common attachment points 40 on the medial and lateral portions of collar 34.

[0050] Yet another aspect of the present invention relates to an internal reinforcement structure that provides limited side to side flexing of the ankle, but snugly retains the heel portion of the foot and provides for limited movement and flexing of the footwear in accordance with the movement of the foot. Internal reinforcement structures of the present invention may be provided having varying degrees of stiffness, and thereby enhancing various footwear performance characteristics. The internal reinforcement structure may be employed with a flexible outer shell comprising leather, fabric, or a flexible plastic material, or a combination of such materials, to provide footwear having a higher degree of support and rigidity, without requiring a rigid outer shell. Thus, the desirable performance characteristics of footwear constructed from substantially rigid materials may be provided in footwear constructed from more comfortable, breathable materials using the internal reinforcement structure of the present invention.

[0051] The internal reinforcement structure is preferably mounted intermediate the exterior and interior surfaces of the footwear. Because the internal reinforcement structure is flexible, it conforms to the shape of the foot and moves to accommodate movement of the ankle in lateral directions, yet it provides firmness and stability characteristic of footwear having rigid or semi-rigid outer shells, such as ski boots. The internal reinforcement structure of the present invention may be provided using a variety of structures, ranging from a perforated sheet of material, such as a plastic material, to the support strips described below.

[0052] FIGS. 3-11 illustrate various embodiments of suitable internal reinforcement structures of the present invention. FIGS. 3 and 4 show simplified internal reinforcement structures according to the present invention. This reinforcement structure comprises at least two support strips 50 and 52 that criss-cross around the heel portion of the footwear. One end of each of support strips 50 and 52 is mounted on structural collar 34 at corresponding attachment points 54 on medial and lateral portions of collar 34, while the other end of each of the support strips is mounted to a structural footwear component in proximity to the sole at corresponding attachment points 56. Attachment of strips 50 and 52 to collar 34 at attachment points 54, and to a structural portion of the footwear at attachment points 56, is preferably pivotable and may be provided, for example, by rivets. According to the embodiment illustrated in FIGS. 3 and 4, a sole plate 55 is provided having a rigid or semi-rigid floor that conforms generally to the bottom surface of the foot, a rim 57 extending upwardly from the floor for attachment of structural elements, and tabs 59 extending upwardly and, preferably, sloped inwardly, in a forefoot portion. As shown in FIG. 4, tabs 59 may be provided with slots 61 or other attachment means for attachment of various elements, such as support straps, mounted on the exterior or interior of the footwear. Although sole plate 55 is illustrated in FIG. 3 as extending substantially the full length of the insole, a partial length sole plate may be provided for certain embodiments. Sole plate 55 may be constructed from reinforced fiberglass, semi-rigid plastics, including injection molded plastics, synthetic resins, metallic sheet materials, or composite materials. The sole plate may be constructed as a plurality of layers having desired properties bonded together.

[0053] Preferred internal reinforcement structures of the present invention comprise at least two support strips mounted to an upper collar, the strips criss-crossing one another around the heel portion of footwear, as shown in FIGS. 3 and 4. In this embodiment, downward movement of collar 34 is prevented and the heel is snugly retained in the heel portion of the footwear, while side to side flexing of the ankle and leg is permitted. In this embodiment, strip 50 crosses downwardly from the medial side to the outer lateral side of the footwear, while strip 52 crosses downwardly from the outer lateral side to the inner medial side of the footwear. According to a preferred embodiment, strips 50 and 52 are arranged at an angle of about 35° to about 60° with the plane of sole plate 55 or the plane of inner surface of sole 16.

[0054] Support strips 50 and 52 are non-stretchable in the direction of their longitudinal axes, but are bendable and flexible to conform to the configuration of the footwear and the foot. Strips 50 and 52 are preferably fabricated, for example, from reinforced fiberglass, relatively thin layers of metals, such as spring steel, substantially rigid plastics, synthetic resins, composite materials, and the like. In a preferred embodiment, thin metallic strips comprising, for example, spring steel, may be curved to the desired shape for criss-crossing the heel portion and then heat treated to enhance the hardness and rigidity of the strips.

[0055] The configuration, width and thickness of support strips varies with the type of footwear, the materials and construction of the other footwear components, the type of reinforcement structure, and the like. In general, the support strips preferably have a width of at least about {fraction (1/16)}″ and, more preferably at least about ⅛.″ Support strips having a generally small thickness are preferred to provide greater comfort and to reduce interference with the fit and movement of the footwear. Reinforcing strips 50 and 52 are preferably positioned intermediate the exterior and interior surfaces of the footwear.

[0056] The exterior layer of the footwear may be constructed from a material that has a moderate degree of stiffness and serves to contain any outward flexing of reinforcing strips 50 and 52. Various plastic materials, leather and reinforced fabric materials are suitable. Alternatively or additionally, containment of the reinforcing structure may be provided by inserting another layer intermediate the exterior surface of the footwear having a reinforcing structure wrapping horizontally around the heel. FIG. 5 illustrates the placement of the internal reinforcement structure of the present invention in a boot.

[0057] FIGS. 3 and 4 illustrate alternative embodiments of collar 34 and collar 34′. Collar 34, as shown in FIG. 3, comprises a rigid, curved element that provides attachment points for reinforcing strips 50 and 52. Collar 34 extends approximately halfway around the ankle or lower leg of a wearer. Alternatively, collar 34′, as shown in FIG. 4, comprises an upper rim 35 extending away from the interior of the footwear. Collar 34′ additionally comprises a heel support portion 37 extending downwardly and covering a portion of the ankle or the back portion of the lower leg of a wearer. The collar may, alternatively, extend for substantially the full circumference of the ankle or lower leg of the wearer and include means for fastening or adjusting the collar to permit entry and withdrawal of a foot from the footwear.

[0058] FIGS. 6 and 7 illustrate footwear of the present invention incorporating another arrangement of an internal reinforcement structure. Specifically, in addition to collar 34, reinforcing strips 50 and 52 and sole plate 55, the internal reinforcement structure includes forward support stays 65 provided on either side of upper 15 in proximity to the lacing or fastening structure. Support stays 65 are arranged generally vertically with respect to the upper surface 17 of sole 16 and, according to the embodiment illustrated in FIG. 6, support stays 65 extend from an upper area, where they are fastened to collar 34, to an intermediate location above sole 16. According to another embodiment, illustrated in FIG. 7, support stays 67 extend from an upper area, where then are fastened to collar 34, to a location in proximity to sole 16. As shown in FIG. 7, support stays 67 are pivotably attached to collar 34, criss cross over the top of the foot, and are pivotably attached to sole plate 55, such as at tabs 59. Support stays 65 and 67 are substantially rigid and have properties similar to or the same as reinforcing strips 50 and 52.

[0059] FIG. 8 illustrates yet another embodiment of an internal reinforcing structure comprising a plurality of criss-crossing support strips, specifically two pairs of strips, 50, 50′, 52 and 52′. Each of the reinforcing strips is mounted to collar 34 at one end, and to sole 16 or a structural element in proximity to sole 16 at the other end. Attachment of support strips to collar 34 and/or other structural elements is preferably provided by pivotable attachment means, such as rivets. Each pair of strips 50, 50′ and 52, 52′ is preferably mounted so that the strips follow paths that are substantially parallel to one another. And, the cross-crossing pairs of support strips are preferably arranged in a substantially mirror image relationship. The configuration and composition of support strips is preferably as described above.

[0060] FIG. 9 illustrates yet another internal reinforcement structure of the present invention. According to this embodiment, a plurality of transverse strips 60, 60′, 60″, etc. and 62, 62′, 62″, etc. criss-cross one another and are anchored, at opposite ends, to collar 34 and/or a structural component of the footwear in proximity to the sole, or to another strip. Thus, support strip 60 is fastened to collar 34 at attachment point 64 and to support strip 62′ at attachment point 66. Similarly, support strip 62 is attached to collar 34 at attachment point 64,′ and is attached to a transverse support strip terminating above the sole at an attachment point (not shown). According to preferred embodiments, support strips 60 and 62 do not fasten to both collar 34 and an attachment point near the sole. Rather, strips that are fastened to an attachment point on collar 34 attach, at their other ends, to the terminal end of a transverse strip located between collar 34 and the sole. Similarly, strips that are fastened in proximity to the sole attach, at their other ends, to the terminal end of a transverse strip located between collar 34 and the sole. In this fashion, a regular network of criss-crossing support strips is provided, with terminating intersections 66, 66′, 66″, etc., on both the medial and lateral sides of the heel portion of the footwear.

[0061] Support strips 60, 60′, 60″, etc. and 62, 62′, 62″, etc., are preferably attached to collar 34 or a structural component of the footwear in proximity to the sole, and to the terminal ends of corresponding transverse strips using pivotable attachment means such as rivets or the like. Thus, each support strip is pivotable about each attachment point. Strips 60, 60′, 60″, etc., are preferably arranged substantially parallel to one another and at substantially right angles to strips 62, 62′, 62″, etc. Likewise, strips 62, 62′, 62″, etc., are preferably arranged substantially parallel to one another and at substantially right angles to strips 60, 60′, 60″, etc. Transverse strips may overlie or underlie one another, but it is preferable that one set of strips, illustrated as strips 62, 62′, 62″, etc., overlie or underlie the other set of strips. The number, size and configuration of support strips may vary, depending on the footwear application and the degree of structural rigidity or flexibility desired. Thus, the illustrated embodiment employs six sets of transverse support strips. Various applications may employ from two to twelve or more sets of support strips of varying sizes and configurations. The support strips are preferably constructed as described above.

[0062] FIG. 10 illustrates yet another embodiment of an internal reinforcement component and footwear of the present invention incorporating the internal reinforcement component. According to this embodiment, transverse support strips 60, 60′, 60″, etc. and 62, 62′, 62″, etc., are provided and, additionally, strips 70, 70′, 70″, etc. are provided in a generally horizontal orientation and attached to the reinforcement structure, preferably using pivotable attachment means, at attachment points 66, 66′, 66″, etc. One or more horizontal support strips may be provided, depending on the degree and type of reinforcement support desired. For certain applications, for example, a single horizontal support strip may be provided in a central area between collar 34 and the sole. This strip may be wider or thicker than the transverse strips to provide additional support. Alternatively, support strips 70 and 70′″ may be provided only in proximity to collar 34 and the sole of the footwear.

[0063] FIG. 11 illustrates yet another embodiment of the internal reinforcement structure of the present invention in which transverse support straps 60, 60′, 60″, etc., and 62, 62′, 62″, etc., overlie and underlie one another in a woven pattern. Additionally, a vertical support strip 72 may be provided that is attached at attachment points 64 and 68 to provide a different degree or type of reinforcement. For certain applications, for example, a single vertical support strip may be provided in a central medial and in a central lateral location of the reinforcement structure as it is mounted in the footwear or, for other applications, a plurality of vertical strips may be provided. The vertical strip(s) may be thicker or thinner and narrower or wider than the transverse strips.

[0064] FIG. 12 illustrates another embodiment of footwear in the form of an outdoor boot having many key features of the present invention. As shown in FIG. 12, footwear 100 comprises an outer sole 102, a toe portion 104, heel portion 106, a footwear closure/fastening system that operates using laces running through eyelets 108, and a tongue or fold 110 forming a part of the closure system These components are well known in the art. Features of the present invention, described below, may also be used with other standard footwear types and features.

[0065] Footwear 100 comprises a flexible collar 112 that is attachable and detachable in the area of the footwear closure by means of a fastener 114. Flexible collar may comprise any durable material having flexibility sufficient to conform to the ankle or lower leg of the wearer. Materials such as nylon webbing are suitable. The fastener and closure system for the collar may be provided in the front and/or rear of the footwear.

[0066] Optional front tension straps 116 criss-cross the footwear in the front, and optional rear tension straps 118 cross-cross the footwear in the rear portion of the footwear. Similar external straps are disclosed earlier in this application and the earlier description applies in this embodiment as well. Tension straps 116 and 118 are preferably adjustable by means of an adjustment mechanism 119. The tension straps may be anchored at one end by fastening in a sewn or fastened layer of the footwear, as illustrated, and may be anchored at the other end to the flexible collar, or to a collar connector 120 provided in proximity to collar 112. Tension straps 116 and/or 118 are preferably fastened to a lower portion of collar 112 or collar connector 120. The point of fastening to collar 112 or collar connector 120 may be pivoting or fixed, and may be detachable.

[0067] Footwear 100, as illustrated in FIG. 12, additionally comprises front compression strips 122 and/or rear compression strips 124 as an internal reinforcement structure. These compression strips have properties and function similarly to the reinforcement strips described above, but differ slightly in placement. It will be recognized by those of ordinary skill in the art that compression strips and tension straps may be used in combination, as illustrated and described, for particular purposes. For other purposes, one may wish to use one or both sets of tension straps without the internal reinforcement structure, and vice versa. Additionally, although both front and rear compression strips are illustrated, a single set may be employed for certain types of footwear. Any combination of front and/or rear tension straps may be used alone or in combination with any combination of front and/or rear compression strips. Similarly, any combination of front and/or rear compression strips may be used alone or in combination with any combination of front and/or rear tension straps.

[0068] Compression strips 122 and 124 criss-cross the front and heel portion of the footwear, respectively, beneath the outer surface of the footwear, and are anchored at one end in proximity to the sole and at the other end in proximity to the collar and/or collar connector. Compression strips 122 and 124 may be mounted to a rigid or semi-rigid sole plate 126 by means of pivotable or fixed attachment points and, likewise, may be mounted to collar 112 or collar connector 120 by means of pivotable or fixed attachment points. In the embodiment illustrated in FIG. 12, compression strips 122 and 124 are attached to collar 112 or collar connector 120 in proximity to the attachment points of the tension straps.

[0069] Placement of the compression strips is important and may vary for particular footwear applications. In the embodiment illustrated in FIG. 12, both upper and lower attachment points for rear compression strips 124 and front compression strips 122 are behind and in front of, respectively, a midpoint of the heel portion of the footwear. Thus, the compression strips form a rather shallow “X.” Suitable materials of construction for compression strips are as described previously.

[0070] FIG. 13 illustrates yet another footwear embodiment of the present invention. Footwear 101 comprises an outer sole 103, a toe portion 105, heel portion 107, a footwear closure/fastening system that operates using laces running through eyelets 109, and a tongue or fold 111 forming a part of the closure system. These components are well known in the art. Features of the present invention, described below, may also be used with other standard footwear types and features.

[0071] Footwear 101 comprises a flexible collar 113 that is attachable and detachable in the area of the footwear closure by means of a fastener 115. Flexible collar 113 may comprise any durable material having flexibility sufficient to conform to the ankle or lower leg of the wearer. Materials such as nylon webbing are suitable. The fastener and closure system for the collar may be provided in the front and/or rear of the footwear.

[0072] Optional front tension straps 117 criss-cross the footwear in the front, and optional rear tension straps 119 criss-cross the footwear in the rear portion of the footwear. Similar external straps are disclosed earlier in this application and the earlier description applies in this embodiment as well. Tension straps 117 and 119 are preferably adjustable by means of an adjustment mechanism 121. The tension straps may be anchored at one end by fastening in a sewn or fastened layer of the footwear, as illustrated, and may be anchored at the other end to the flexible collar, or to a structural piece 123 that is rigid or semi-rigid and is provided in proximity to collar 113. As illustrated in FIG. 13, structural piece 123 forms a layer below the outer layer of collar 113 and is constructed of a rigid or semi-rigid material that provides a durable anchor for connection of tension straps and/or compression strips. Structural piece 123 may be constructed, for example, from metallic or plastic materials, fiberglass, reinforced plastics and fiberglass, and the like. Structural piece 123 preferably is not coextensive with collar 113, and circles the ankle or heel portion of the footwear in a configuration that is less than a semi-circle. The front edges of structural piece 123 are preferably to the rear of the lateral and medial midpoints of collar 113.

[0073] Tension straps 117 and/or 119 are preferably fastened to a lower portion of collar 113 or structural piece 123. The point of fastening to collar 112 or structural piece 123 may be pivoting or fixed, and may be detachable.

[0074] Footwear 101, as illustrated in FIG. 13, additionally comprises rear compression strips 125 as an internal reinforcement structure. These compression strips have properties and function similarly to the reinforcement strips described above, but differ slightly in placement. It will be recognized by those of ordinary skill in the art that compression strips and tension straps may be used in combination, as illustrated and described, for particular purposes. For other purposes, one may wish to use one or both sets of tension straps without the internal reinforcement structure, and vice versa. Compression strips 125 criss-cross the heel portion of the footwear, beneath the outer surface of the footwear, and are anchored at one end in proximity to the sole and at the other end in proximity to the collar and/or structural piece. Compression strips 125 may be mounted to a rigid or semi-rigid sole plate 127 by means of pivotable or fixed attachment points and, likewise, may be mounted to collar 113 or structural piece 123 by means of pivotable or fixed attachment points. In the embodiment illustrated in FIG. 13, compression strips 125 are attached to structural piece 123 in proximity to the attachment points of the tension straps 117 and 119. In fact, in the embodiment illustrated, the tension straps and compression strips all share the same attachment point.

[0075] Placement of the compression strips is important and may vary for particular footwear applications. In the embodiment illustrated in FIG. 13, both upper and lower attachment points for rear compression strips 125 are behind a midpoint of the heel portion of the footwear. Thus, the compression strips form a rather shallow “X.” Additionally, the intersection of the compression strips is preferably above a midpoint of the strips. This permits the strips to intersect at a point above the heel and is generally more comfortable to the wearer. The intersection of the compression strips forming the “X” may be adjusted, depending upon the type of footwear and the activity of the wearer.

[0076] While the footwear and footwear components of the present invention have been described with respect to certain preferred embodiments thereof ad many details have been set forth for purposes of describing the invention in detail, it will be recognized that additional configurations, embodiments and materials may be used without departing from the invention.

Claims

1. An article of footwear a woven heel component having a first set of strands oriented at from 60° to 120° to the plane of a sole of the footwear article and another set of strands oriented at right angles to the first set of strands.

2. An article of footwear according to

claim 1, wherein the woven heel component is provided as a footwear liner.

3. An article of footwear comprising external heel straps including a first strap mounted at a medial side portion of the footwear article and wrapping downwardly around the heel and laterally to a lower position on the lateral side of the footwear article and a second strap mounted at a lateral side portion of the footwear article and wrapping downwardly around the heel and laterally to a lower position on the medial side of the footwear article, the first and second straps thereby criss-crossing at a generally central heel portion of the footwear article.

4. An article of footwear comprising external forefoot straps including a first strap mounted at a medial side portion of the footwear article and extending downwardly and laterally across the top of the forefoot to a lower position on the lateral side of the footwear and a second strap mounted at a lateral side portion of the footwear article and extending downwardly and laterally across the top of the forefoot to a lower position on the medial side portion of the footwear article, the first and second straps thereby criss-crossing at a generally central forefoot portion of the footwear article.