GEL PAD FOR FOOTWEAR

Abstract

A gel pad for use in a sockliner designed to strategically support the weight of the wearer and to distribute underfoot pressure. The gel pad includes a base having a top face, a bottom face and a central floor portion associated with the bottom face, an outer flange positioned on the perimeter of the bottom face surrounding the central floor portion, and a plurality of spaced apart hollow pillars positioned across the surface of the central floor portion. The network of hollow pillars support the body weight of the wearer without bottoming out and the pillars are sufficiently spaced from each other to allow for expansion horizontally when the pillars are compressed vertically. Each of the pillars may be substantially octagonally shaped.

Description

BACKGROUND OF THE INVENTION

The present invention is directed to a footwear construction and, more particularly, to a gel pad having a network of hollow motion pillars for engaging the wearer's foot during impact.

Numerous attempts have been made over the years to incorporate into footwear means for providing improved cushioning and support within a shoe's construction. Most articles of footwear are generically designed to accommodate as many foot shapes as possible in order to appeal to a broad range of consumers. Consequently, the resulting fit and comfort will vary greatly from person to person because satisfying the ergonomic needs of such a broad range of individuals with a single design is extremely difficult.

Shoes, at their most fundamental level, are intended to provide protection and comfort to the human foot during the course of day-to-day activities. Footwear designs have varied greatly over time as well as from culture to culture, with the predominate focus relating to functionality. Typically, shoe interiors contain a variety of hard materials and/or low density foam and often include substantially flat surfaces which come into direct contact with the foot. Such materials are employed within the construction of footwear interiors in an attempt to provide support and/or cushioning. While these types of materials may provide comfort in the short-term, such materials quickly compress, thus failing to provide sufficient support and/or cushioning over the course of an entire day.

In addition, current sockliners are intended to support the foot and provide cushion thereto. The point of the heel striking the ground typically takes the greatest amount of pounding. The heel requires extra cushioning in order to provide continuous comfort and longer wearing time. In contrast, most sockliners are one thin layer of foam material. This does not provide enough support under the heel to absorb shock from striking the ground.

In order to correct for the design deficiencies of such footwear interiors, consumers often purchase aftermarket insoles to insert within shoes they find uncomfortable in an attempt to compensate for the shoe's deficiencies in support and/or comfort. Although many of these aftermarket insoles are marketed as a simple solution for increasing support and/or comfort, their use is often associated with fit problems and ultimately fail to deliver the improvements promised. This is because the space and structural limitations of a variety of footwear interiors were not considered when these insoles were designed.

Individuals generally find footwear uncomfortable after a full day of wear, regardless of whether the individual is relying only on the support elements built within the shoe's structure or if they have added additional support in the form of a purchased aftermarket insole. Indeed, numerous combinations of shoe constructions and/or separately sold insoles have been employed in an attempt to provide support and/or comfort. In particular, such current support elements fail to adequately distribute an individual's weight during footstrike, causing most of the force to be borne by the individual's heel. It is therefore desirable to provide a gel pad for various types of footwear which provides increased comfort and support by receiving the heel during footstrike.

SUMMARY OF THE INVENTION

The present invention is directed to a gel pad which uses pressure distribution technology to adequately distribute an individual's weight and provides increased comfort and support to the wearer. The present gel pad is designed to be positioned in the center heel area of footwear and includes a network of hollow motion pillars that provide perceivably noticeable cushioning and improved support over the course of an entire day without bottoming out. Each hollow pillar is sized, shaped and spaced strategically to support the weight of the wearer and distribute underfoot pressure.

More particularly, the gel pad includes a base having a top face for receiving a heel and/or positioning it within a shoe and a bottom face having a central floor portion and an outer flange which cooperate to provide structural integrity to the gel pad. A plurality of hollow pillars are positioned in spaced apart relationship on the surface of the central floor portion, the top surfaces of each of the pillars being substantially parallel to the outer flange. The plurality of pillars may be positioned to point downward such that each of the pillar top surfaces engage the next interior layer of the shoe. The pillars may be evenly spaced in rows across the central floor portion bordered by the outer flange. Each of the pillars may be preferably sized to cooperate together in order to provide support and/or cushioning to the wearer's heel during footstrike. In one embodiment, each of the pillars may be substantially octagonally shaped.

The combination of the central floor portion, the plurality of hollow pillars, the outer flange, and the use of a gel type material that substantially maintains its form all function to improve the distribution of the underfoot pressure. It is also generally recognized that the gel pad of the present invention is more resistant to “bottoming out”, which for purposes of this disclosure, means that the gel pad will not reach a threshold of force where the gel type material will not further compress. As pressure is applied to the present gel pad, the hollow pillars compress vertically, causing them to expand horizontally. The spacing between the pillars and the hollow cavity within each pillar provide space for each pillar to expand horizontally, allowing for additional compression and cushioning without resistance or pressure increases due to bottoming out.

In alternative embodiments, the present gel pad may be positioned in the forefoot region, the midfoot region and/or the hind foot region to provide support and/or cushioning to said regions. It is further understood that a plurality of gel pads may be positioned within various parts of the shoe to provide support and/or cushioning to multiple regions of the foot simultaneously.

It is also recognized that the present gel pad may be directly incorporated into a sockliner fixed within a particular shoe, or it may be incorporated into an aftermarket sockliner, to provide improved support and/or comfort over the course of an entire day. The gel pad may also be integrated with a strobel insole or insole board as well. It could likewise be left uncovered or a removable sockliner could be placed over it.

Specific advantages and features of the present invention will be apparent from the accompanying drawings and the description of several illustrative embodiments of the present invention.

DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a bottom perspective view of one embodiment of a gel pad constructed in accordance with the teachings of the present invention.

FIG. 2 is a bottom plan view of the gel pad of FIG. 1.

FIG. 3 is a cross-sectional view of the gel pad of FIG. 2 taken along lines 3-3.

FIG. 4 is a top plan view of another embodiment of a gel pad integrated into a sockliner constructed in accordance with the teachings of the present invention.

FIG. 5 is a cross-sectional view of the gel pad and sockliner of FIG. 4 taken along line 5-5.

It should be understood that the present drawings are not necessarily to scale and that the embodiments disclosed herein are sometimes illustrated by fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should also be understood that the invention is not necessarily limited to the particular embodiments illustrated herein. Like numbers utilized throughout the various figures designate like or similar parts or structure.

DETAILED DESCRIPTION

Footwear generally includes an upper and a sole assembly that is affixed to the upper. The sole assembly typically includes a peripheral shape designed to conform to the shape of a wearer's foot. For ease of reference herein, the human foot may be generally considered to have three regions: the forefoot region (area adjacent the toes and which underlies at least a portion of the ball of a wearer's foot), the midfoot region (area adjacent the medial arch, between the forefoot and the hind foot regions and which underlies at least a portion of the arch of a wearer's foot) and the hind foot region (area adjacent the heel, including the center heel area and which underlies at least an area of a wearer's heel). When referring to such locations and the way in which the regions of the foot are received within a shoe, these terms should be interpreted to include those areas that are disposed generally (and not necessarily directly) beneath the corresponding elements of the foot. It should be understood, however, that the boundaries between the regions are not precise and that these terms should be interpreted loosely and with a great deal of flexibility.

Referring now to the drawings, more particularly by reference numbers, FIGS. 1 and 2 illustrate one embodiment of a gel pad 10 constructed in accordance with the teachings of the present invention. Although the present gel pad 10 is configured and discussed herein as being positioned in the center heel area of footwear in order to provide improved support and/or comfort to the wearer, it is recognized and anticipated that it can be configured and positioned at other locations within a shoe as will be hereinafter explained. The present gel pad 10 is also generally incorporated into other components of a shoe as will be hereinafter discussed but could also be incorporated into an aftermarket insole product as well.

The gel pad 10 includes a base 12 that may be formed in any suitable style or shape having a top face 14 and a bottom face 16 as best illustrated in FIGS. 3 and 5. Preferably, the top face 14 is shaped to conform to the wearer's heel, or other portion of a wearer's foot, and the bottom face 16 includes a central floor portion 18A and an outer flange 20 which cooperate together to provide structural integrity to the overall gel pad 10. In one embodiment, the base 12 includes a thickness in the range of between approximately 0.25 mm and approximately 10 mm, a length in the range of between approximately 10 mm and approximately 100 mm measured between the two furthest points along a longitudinal distance between points 28 and 30 illustrated in FIG. 2, and a width in the range of between approximately 10 mm and approximately 70 mm likewise measured between the two furthest points along a transverse distance between points 32 and 34 in FIG. 2. A plurality of hollow shaped pillars 22 are positioned and located on the central floor portion 18A as best illustrated in FIG. 3, the top surfaces 24 of each of the pillars 22 extending above floor portion 18A and being substantially parallel to the outer flange 20.

The gel pad 10 of FIGS. 1 and 2 is constructed to receive the heel portion of a wearer's foot and to distribute the wearer's weight during footstrike, providing support and/or cushioning thereto. To this end, the gel pad 10, including base 12 and pillars 22, may be fashioned from any suitable gel type material including, but not limited to, thermoplastic rubber, Styrene Ethylene Butylene Styrene (SEBS), silicone, injection molded polyurethane, compression molded polyurethane, poured polyurethane and the like. The gel pad 10 preferably has a hardness range from about 20 to about 60 on the Asker “C” Scale. Depending on the type of material used in forming the gel pad 10, the base 12 may be substantially transparent such that each of the pillars 22 may be visible when viewing the top face 14 of the gel pad 10. In addition to being transparent, the gel pad 10 could have a color application (paint) on its bottom face that would project a second color upwards through the pillars and top face. In this regard, it is also recognized that although it is generally preferred that the hardness range for both the base 12 and the pillars 22 be in the range from about 20 to about 60 Asker “C” Scale, it is also recognized and anticipated that the hardness of base 12 may differ from the hardness of the pillars 22 while both such hardness numbers fall within the preferred range.

In one embodiment, the hollow shaped pillars 22 may be evenly spaced across the central floor portion 18A, the pillars 22 being bordered by the outer flange 20. In another embodiment, the space between the pillars 22 may range from between approximately 1 mm and approximately 10 mm, the pillars 22 being spaced as desired in order to support and/or cushion the heel during footstrike and to allow sufficient space for horizontal expansion under compression. Furthermore, the pillars 22 may be organized into rows extending across the surface of the central floor portion 18A. Each of the pillars 22 is substantially column-shaped, the height of each pillar 22 being preferably in the range of between approximately 0.5 mm and approximately 30 mm, the length of each pillar being preferably in the range of between approximately 0.5 mm and approximately 30 mm; the thickness of the walls forming each respective pillar 22 being preferably in the range of between approximately 0.5 mm and approximately 10 mm; and the hollow space between two opposed walls within each pillar being preferably in the range of between approximately 0.5 mm and approximately 29.75 mm. Based on the expected body weight, compression % and load supported by each pillar 22, the pillar heights and network spacing can be determined by a person skilled in the art.

The pillars 22 are oriented to distribute body weight during footstrike without “bottoming out” and strategically allocate underfoot pressure. Furthermore, each of the pillars 22 may be substantially octagonally shaped and preferably size to cooperate together in order to provide support and/or cushioning to the wearer's heel during footstrike. It is understood that in alternative embodiments, each of the pillars 22 may be fashioned into other shapes, as desired, to accommodate various alternative designs of the gel pad 10 without departing from the teachings and practice of the present invention. In addition, the gel pad 10 could be designed to have different surface areas, shapes and thicknesses due to gender and foot sizes. The overall shape of the gel pad 10 illustrated in FIGS. 1, 2 and 4 was selected because it substantially conforms to the outline shape of the human heel and substantially covers the heel area. In this regard, it is recognized that the overall shape of pad 10 may change depending upon where it is positioned within a particular shoe.

As illustrated in FIG. 3, in one embodiment of the present pad 10, the height of the central floor portion 18A surrounding the plurality of pillars 22 may be a different height than the floor portion 18B found within the hollow opening of each pillar 22. In this particular embodiment, the pillars 22 are recessed into the base 12. It is understood that in alternative embodiments, the central floor portion 18A may be substantially at the same height or level as the pillar floor portion 18B without departing from the teachings and practice of the present invention. FIG. 3 further illustrates the plurality of pillars 22 pointing towards the bottom face 16 such that each of the top surfaces 24 of the pillars 22 will engage the next component layer of the shoe such as the midsole. This is more clearly seen in FIG. 5. In alternative embodiments, it is envisioned that the plurality of pillars 22 may be positioned to face towards the top face 14 such that each of the top surfaces 24 of the Pillars 22 may directly engage the foot of the wearer.

FIGS. 4 and 5 illustrate still another alternative embodiment of the present gel pad 10 wherein the pad 10 is incorporated directly into a sockliner 26 for positioning the gel pad 10 within the center heel area of the footwear. In this regard, the gel pad 10 is typically positioned on the underneath side of the sockliner 26 and is generally secured thereto by stitching, adhesives, fusion bonding or by any other coupling process. FIG. 5 illustrates the plurality of pillars 22 pointing downward such that each of the top surfaces 24 of the pillars 22 engages the shoe component located therebelow. The sockliner 26 with gel pad 10 incorporated therein can be permanently attached to a particular shoe construction, or it can be made as an aftermarket insole product.

Although the embodiments of the present gel pad 10 are generally designed to be positioned in the center heel area, it is understood that in alternative embodiments, the gel pad 10 may be positioned in the forefoot region, the midfoot region or the hind foot region of a particular shoe to provide support and/or cushioning to those regions of the foot without departing from the teachings and practice of the present invention. In alternative embodiments, it is further envisioned that a plurality of gel pads 10 may be positioned within various parts of the shoe to provide support and/or cushioning to multiple regions of the foot simultaneously.

Further, the overall dimensions of the embodiments of the present gel pad 10 as well as the specific shape and configuration of the various sections thereof are also subject to wide variations and may be sized and shaped into a wide variety of different sizes and configurations so as to be compatible with the size and shape of the particular footwear into which the present structure may be inserted and/or secured, or to conform to any space limitations associated therewith without impairing the teachings and practice of the present invention.

It is also recognized and anticipated that the base 12 and the plurality of pillars 22 can be molded into a one-piece pad 10. It is also understood that the base 12 can be made separate and apart from the pillars 22 and that these components could be separate members which are attached together in a unitary fashion. It is also anticipated that the plurality of pillars 22 could be formed on a thin sheet of material and such sheet of material could then be attached to the base 12. Other assembly configurations are likewise envisioned.

Still further, the shape, size and height of each pillar within the network of pillars 22 associated with a particular gel pad 10 could vary between each other within such network, and the shape and/or size of each pillar 22 could include any angle or curve found in a geometric shape. In addition, the overall shape of the gel pad 10 could likewise include any angle or curve found in a geometric shape and the pad 10 could be sized and shaped to conform to the particular location within a particular shoe where such pad will be positioned. Nevertheless, regardless of the overall shape, size, height and configuration of the various components of the present gel pad 10, the final configuration is designed so as to deliver better weight and pressure distribution across a broader area thereby lowering foot pressure and providing improved shock absorption during footstrike. The present pillars 22 compress and recover to their original size giving superior cushioning and support to a wearer's foot. This improves cushioning and comfort and provides the wearer with immediate benefits as compared to the current sockliners presently in use. Other advantages are likewise anticipated.

It is also understood that various modifications may be made to all of the various embodiments disclosed herein without departing from the spirit and scope of the present invention.

Thus, there has been shown and described several embodiments of a novel gel pad. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required.” Many changes, modifications, variations and other uses and applications of the present invention will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.

Claims

1. A gel pad comprising:

a base having a top face, a bottom face, and a central floor portion associated with said bottom face;

an outer flange positioned on the perimeter of said bottom face surrounding said central floor portion; and

a plurality of spaced hollow pillars positioned across the surface of said central floor portion.

2. The gel pad of claim 1 wherein said pad is formed from a material selected from the group consisting of thermoplastic rubber, SEBS, silicone and polyurethane.

3. The gel pad of claim 2 wherein the material used in forming said base is substantially transparent.

4. The gel pad of claim 1 wherein the bottom face of the base includes a color application that will project upwards to the top face.

5. The gel pad of claim 1 wherein the pillars are substantially octagonally shaped.

6. The gel pad of claim 1 wherein the pillars are evenly spaced across the surface of the central floor portion.

7. The gel pad of claim 1 wherein the pillars are organized into rows extending across the surface of the central floor portion.

8. The gel pad of claim 1 wherein said pad is integrated into a sockliner.

9. The gel pad of claim 1 wherein said pad is integrated into an insole.

10. The gel pad of claim 1 wherein at least a portion of each of said plurality of pillars is recessed in said base.

11. The gel pad of claim 1 wherein said base has a hardness in the range from about 20 to about 60 on the Asker C Scale.

12. The gel pad of claim 1 wherein each of said pillars has a hardness in the range from about 20 to about 60 on the Asker C Scale.

13. The gel pad of claim 1 wherein the height of each pillar is in the range of between about 0.5 mm and about 30 mm.

14. The gel pad of claim 1 wherein the hollow space between two opposed walls within each said pillar is in the range of between about 0.5 mm and about 29.75 mm.

15. The gel pad of claim 1 wherein the thickness of the walls forming each said pillar is in the range of between about 0.5 mm and about 10 mm.

16. The gel pad of claim 1 wherein the space between said pillars is in the range of between about 1 mm and about 10 mm.

17. A gel pad comprising:

a base having a top face, a bottom face, and a central floor portion associated with the bottom face;

a plurality of spaced apart hollow pillars positioned across the surface of said central floor portion, each of said pillars being substantially octagonally shaped, said pillars being sufficiently spaced from each other to allow for expansion of each said pillar horizontally when said pillars are compressed vertically.

18. The gel pad of claim 17 including an outer flange positioned on the perimeter of said bottom face surrounding said central floor portion.

19. The gel pad of claim 17 wherein the base is made of a transparent material.

20. A sockliner for use in a shoe comprising:

a hindfoot region positioned to underlie at least an area of a wearer's heel, a midfoot region positioned to underlie at least a portion of an arch of a wearer's foot, and a forefoot region positioned to underlie at least a portion of the ball of a wearer's foot;

a pad having a base, said base having a top face, a bottom face, and a central floor portion associated with said bottom face;

an outer flange positioned on the perimeter of said bottom face surrounding said central floor portion; and

a plurality of spaced apart hollow pillars positioned across the surface of said central floor portion;

said pad being incorporated into said sockliner at a predetermined location.

21. The sockliner of claim 20 wherein said plurality of pillars are substantially octagonally shaped.

22. The sockliner of claim 20 wherein said pad is attached to the underneath side of said sockliner.

23. The sockliner of claim 20 wherein said pad is positioned and located in the hindfoot region of said sockliner.

24. The sockliner of claim 20 wherein said pad is positioned and located in the midfoot region of said sockliner.

25. The sockliner of claim 20 wherein said pad is positioned and located in the forefoot region of said sockliner.

26. The sockliner of claim 20 including a plurality of said pads positioned and located at predetermined locations in said sockliner.

27. The sockliner of claim 20 wherein said pillars are evenly spaced across the surface of central floor portion.

28. The sockliner of claim 20 wherein said pillars are organized into rows extending across the surface of said central floor portion.